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<p>This paper presents a proposed triad rapid formative additive manufacturing approach (TRFAM) to produce 3D products made of metal/polymer composite laminates. The process utilizes fused deposition modelling (FDM), single-point incremental forming (SPIF) and CNC machining to fabricate functional 3D composite laminates. The paper investigated two process parameters of SPIF, basically, step size (0.6&#xa0;mm and 0.3&#xa0;mm), and feed rate (250&#xa0;rpm/min and 500&#xa0;rpm/min) and two FDM parameters, mainly, layer thickness (1&#xa0;mm and 2&#xa0;mm) and infill % (80% and 100%) and examined their effects on the formability, surface roughness and adhesion tensile strength of the testing coupons. Results showed that a step size of 0.3&#xa0;mm, feed rate of 500&#xa0;rpm/min, a sheet thickness of 1&#xa0;mm and infill % of 100% yielded optimal coupons quality given the tested conditions. The optimal parameters used to build a 3D laminate model to prove the feasibility. The findings proved the feasibility of the proposed approach by fabricating successfully a scaled 3D outer panel door model of AA6061-T6/PLA composite laminate. The proposed TRFAM approach presented in this work integrates AM, SPIF, CNC for manufacturing large products of composite laminate, that can benefit many industrial sectors such as the automobile, renewable energy industry and the scientific industry.</p>

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Investigating the feasibility of triad additive manufacturing approach on metal/polymer composite laminates for automotive and renewable energy applications

  • 期刊论文

  • 发表日期：

    2026年4月7日

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  • Esraa S. Abdelall,
  • Zaid N Jaradat,
  • Yazan Alsmadi,
  • Abd Al Azeez Melhem

摘要

This paper presents a proposed triad rapid formative additive manufacturing approach (TRFAM) to produce 3D products made of metal/polymer composite laminates. The process utilizes fused deposition modelling (FDM), single-point incremental forming (SPIF) and CNC machining to fabricate functional 3D composite laminates. The paper investigated two process parameters of SPIF, basically, step size (0.6 mm and 0.3 mm), and feed rate (250 rpm/min and 500 rpm/min) and two FDM parameters, mainly, layer thickness (1 mm and 2 mm) and infill % (80% and 100%) and examined their effects on the formability, surface roughness and adhesion tensile strength of the testing coupons. Results showed that a step size of 0.3 mm, feed rate of 500 rpm/min, a sheet thickness of 1 mm and infill % of 100% yielded optimal coupons quality given the tested conditions. The optimal parameters used to build a 3D laminate model to prove the feasibility. The findings proved the feasibility of the proposed approach by fabricating successfully a scaled 3D outer panel door model of AA6061-T6/PLA composite laminate. The proposed TRFAM approach presented in this work integrates AM, SPIF, CNC for manufacturing large products of composite laminate, that can benefit many industrial sectors such as the automobile, renewable energy industry and the scientific industry.