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<p>Continuous Kevlar fiber reinforced thermoplastic (KF-TP) composite filaments have recently been developed for extrusion-based additive manufacturing due to their high specific strength and modulus. However, exposure to elevated temperatures during extrusion from printer nozzles as well as bending of the filaments may affect their mechanical properties. This study aims to evaluate effects of temperature and bending angle on the mechanical performance of a continuous Kevlar fiber-reinforced nylon 6 composite filament. The mechanical, thermal, and morphological characteristics of the filament under different conditions were tested and compared. Filaments went through a nozzle with varying temperatures between 25 and 320&#xa0;°C in different bending angles ranging from 0° to 90°. A newly developed tensile testing procedure was used to evaluate the tensile strength and tensile modulus of the KF-TP composite filament. The composite filament was also characterized using thermal and morphological analyses, including thermogravimetric analysis, differential scanning calorimetry, scanning electron microscope, and optical microscopy. The reduction in mechanical properties is directly attributed to meso-structural damage during the extrusion process by elevated temperature and bending angles. The tensile strength and tensile modulus of the composite filaments decreased with increasing temperature and bending angle. A maximum tensile strength reduction of 35% was observed under 65° bending at 320&#xa0;°C.</p>

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Effect of temperature and bending angle on mechanical behaviors of continuous Kevlar fiber reinforced nylon composite filament for extrusion based additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Yongzhe Yan,
  • Yu-Chao Shih,
  • Ethan Stonecipher,
  • Pixiang Wang,
  • Shaoyang Liu,
  • Selvum Pillay,
  • Haibin Ning

摘要

Continuous Kevlar fiber reinforced thermoplastic (KF-TP) composite filaments have recently been developed for extrusion-based additive manufacturing due to their high specific strength and modulus. However, exposure to elevated temperatures during extrusion from printer nozzles as well as bending of the filaments may affect their mechanical properties. This study aims to evaluate effects of temperature and bending angle on the mechanical performance of a continuous Kevlar fiber-reinforced nylon 6 composite filament. The mechanical, thermal, and morphological characteristics of the filament under different conditions were tested and compared. Filaments went through a nozzle with varying temperatures between 25 and 320 °C in different bending angles ranging from 0° to 90°. A newly developed tensile testing procedure was used to evaluate the tensile strength and tensile modulus of the KF-TP composite filament. The composite filament was also characterized using thermal and morphological analyses, including thermogravimetric analysis, differential scanning calorimetry, scanning electron microscope, and optical microscopy. The reduction in mechanical properties is directly attributed to meso-structural damage during the extrusion process by elevated temperature and bending angles. The tensile strength and tensile modulus of the composite filaments decreased with increasing temperature and bending angle. A maximum tensile strength reduction of 35% was observed under 65° bending at 320 °C.