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Open AccessArticle

Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon Fibers

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Centre for Rapid and Sustainable Product Development, Polytechnic Institute of Leiria, Rua de Portugal, 2430-028 Marinha Grande, Portugal
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Institute for Polymers and Composites/I3N, University of Minho, Campus of Azurém, 4800-058 Guimarães, Portugal
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Plastimago—Transformadora de Plásticos, Lda., Estrada de Leiria, 2430-091 Marinha Grande, Portugal
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Department of Mechanical Engineering, Polytechnic Institute of Coimbra, Rua Pedro Nunes, 3030-199 Coimbra, Portugal
*
Author to whom correspondence should be addressed.
This paper is an extended version of “A Hybrid Processing Approach to the Manufacturing of Polyamide Reinforced Parts with Carbon Fibers” published in the Proceedings of the International Conference on Sustainable and Intelligent Manufacturing, RESIM 2016, Leiria, Portugal, 14–17 December 2016.
J. Manuf. Mater. Process. 2019, 3(2), 35; https://doi.org/10.3390/jmmp3020035
Received: 17 January 2019 / Revised: 18 April 2019 / Accepted: 22 April 2019 / Published: 27 April 2019
This work presents an innovative system that allows the oriented deposition of continuous fibers or long fibers, pre-impregnated or not, in a thermoplastic matrix. This system is used in an integrated way with the filamentary fusion additive manufacturing technology and allows a localized and oriented reinforcement of polymer components for advanced engineering applications at a low cost. To demonstrate the capabilities of the developed system, composite components of thermoplastic matrix (polyamide) reinforced with pre-impregnated long carbon fiber (carbon + polyamide), 1 K and 3 K, were processed and their tensile and flexural strength evaluated. It was demonstrated that the tensile strength value depends on the density of carbon fibers present in the composite, and that with the passage of 2 to 4 layers of fibers, an increase in breaking strength was obtained of about 366% and 325% for the 3 K and 1 K yarns, respectively. The increase of the fiber yarn diameter leads to higher values of tensile strength of the composite. The obtained standard deviation reveals that the deposition process gives rise to components with anisotropic mechanical properties and the need to optimize the processing parameters, especially those that lead to an increase in adhesion between deposited layers. View Full-Text
Keywords: additive manufacturing; fused filament fabrication; oriented extrusion; reinforced composites; carbon fibers; prepregs yarns; thermoplastic composites; polyamide additive manufacturing; fused filament fabrication; oriented extrusion; reinforced composites; carbon fibers; prepregs yarns; thermoplastic composites; polyamide
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Reis Silva, M.; Pereira, A.M.; Alves, N.; Mateus, G.; Mateus, A.; Malça, C. Development of an Additive Manufacturing System for the Deposition of Thermoplastics Impregnated with Carbon Fibers. J. Manuf. Mater. Process. 2019, 3, 35.

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