Durability of Vacuum Infusion Tooling Produced from Fused Granular Fabrication Additive Manufacturing

Fused Granular Fabrication Additive Manufacturing (FGF AM) has the capability to create tooling that is lower cost than conventionally manufactured tooling and still has sufficient properties for many applications. A vacuum infusion (VI) mold was printed from fiberglass-acrylonitrile butadiene styrene (ABS) and evaluated for wear and suitability for small VI runs. The mold was designed to accentuate high wear as a "worst case" scenario. The mold was able to produce 10 parts successfully before any noticeable change occurred to the surface finish. By 14 parts, the surface finish had roughened sufficiently that demolding was difficult and resulted in damage to the part. Profilometry measurements showed a 7 × increase in roughness over the run. No significant tool wear or change in geometry was detected. Even longer life would be expected for typical tooling designs since the test mold was deliberately designed to accentuate wear and demolding issues. Based on these results, similar FGF molds are a feasible option for short run VI production for prototyping or low-volume composites manufacturing, possibly at lower cost and quicker turnaround time than machined aluminum molds.

Tensile and Compression Strength Prediction and Validation in 3D-Printed Short-Fiber-Reinforced Polymers

In the current study, a methodology is validated for predicting the internal spatially varying strength properties in a single 3D-printed bead composed of 13%, by weight, carbon-fiber-filled acrylonitrile butadiene styrene. The presented method allows for the characterization of the spatially varying microstructural behavior yielding a local anisotropic stiffness and strength that can be integrated in a finite element framework for a bulk estimate of the effective stiffness and strength. The modeling framework is presented with a focus on composite structures made from large area additive manufacturing (LAAM). LAAM is an extrusion-based process yielding components on the order of meters, with a typical raster size of 10 mm. The presented modeling methods are applicable to other short-fiber-reinforced polymer processing methods as well. The results provided indicate the modeling framework yields results for the effective strength and stiffness that align with experimental characterization to within ∼1% and ∼10% for the longitudinal compressive and tensile strength, respectively, and to within ∼3% and ∼50% for the longitudinal compressive and tensile stiffness, respectively.

Fiber Orientation Quantification for Large Area Additively Manufactured Parts Using SEM Imaging

Polymer-based additively manufactured parts are increasing in popularity for industrial applications due to their ease of manufacturing and design form freedom, but their structural and thermal performances are often limited to those of the base polymer system. These limitations can be mitigated by the addition of carbon fiber reinforcements to the polymer matrix, which enhances both the structural performance and the dimensional stability during cooling. The local fiber orientation within the processed beads directly impacts the mechanical and thermal performances, and correlating the orientation to processing parameter variations would lead to better part quality. This study presents a novel approach for analyzing the spatially varying fiber orientation through the use of scanning electron microscopy (SEM). This paper presents the sample preparation procedure including SEM image acquisition and analysis methods to quantify the internal fiber orientation of additively manufactured carbon fiber-reinforced composites. Large area additively manufactured beads with 13% by weight large aspect ratio carbon fiber-reinforced acrylonitrile butadiene styrene (ABS) pellets are the feedstock used in this study. Fiber orientation is quantified using the method of ellipses (MoE), and the spatial change in fiber orientation across the deposited bead cross-section is studied as a function of process parameters including extrusion speed, raster height, and extrusion temperature zones. The results in the present paper show the results from the novel use of SEM to obtain the local fiber orientation, and results show the variation in alignment within the individual processed bead as well as an overall aligned orientation state along the direction of deposition.