Improved Deposition Rates in Additive Manufacturing of Commingled Tow-Based Continuous Fiber-Reinforced Composites via Alternating Tow Positioning
摘要
Additive manufacturing using continuous fiber-reinforced commingled tow holds the potential to enable the fabrication of continuous fiber-reinforced high-volume fraction composite structures suitable for a wide range of high-performance applications while radically reducing the required tooling. Although improvements in mechanical performance can be achieved through modifications in feedstock materials, process parameters, and post-processing, there are trade-offs in terms of manufacturability. A balance between optimized process parameters, including temperature, consolidation pressure, and speed versus improved tow positioning to enhance fiber orientation and packing, is crucial to producing high-quality composites. In this study, two different tow-layering strategies, layer-by-layer and alternating tow deposition are considered for depositing E-glass/PETG commingled tow onto the tool surface to manufacture high-quality unidirectional composite beams. A custom gantry-style continuous fiber extrusion system is employed in order to manufacture E-glass/PETG composite beams using the layer-on-layer and alternating tow deposition approaches. The volume fraction results of the constituent material and metallographic analysis demonstrate an increased constituent volume fraction and an improved fiber distribution in the beams that were manufactured using the alternating tow deposition approach compared to the layer-on-layer approach. Tests utilizing dynamic mechanical analysis demonstrate that the alternating tow method achieves comparable composite quality at the higher manufacturing rate compared to layer-on-layer tow stacking demonstrating that material deposition rates can be accelerated by tow stacking position in addition to changes in processing parameters.