Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts

Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. Howe...

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Bibliographic Details
Published in:Polymers 2023-10, Vol.15 (19), p.3975
Main Authors: Baranowski, Michael, Shao, Zijin, Spintzyk, Alexander, Kößler, Florian, Fleischer, Jürgen
Format: Article
Language:English
Subjects:
3D printing
Additive manufacturing
Aerospace engineering
Carbon
Carbon fiber reinforced plastics
Continuous fibers
Continuous sintering
Fiber reinforced polymers
Finite element method
Heat affected zone
Laser sintering
Lasers
Manufacturing
Mechanical properties
Polymer industry
Polymer melts
Polymers
Simulation
Sintering
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Summary:Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. However, the existing additive manufacturing processes for CCFRP parts have numerous disadvantages. Resin- and extrusion-based processes require time-consuming and costly post-processing to remove the support structures, severely restricting the design flexibility. Additionally, the production of small batches demands considerable effort. In contrast, laser sintering has emerged as a promising alternative in industry. It enables the creation of robust parts without needing support structures, offering efficiency and cost-effectiveness in producing single units or small batches. Utilising an innovative laser-sintering machine equipped with automated continuous fibre integration, this study aims to merge the benefits of laser-sintering technology with the advantages of continuous fibres. The paper provides an outline, using a finite element model in COMSOL Multiphysics, for simulating and identifying an optimised operating point range for the automated integration of continuous fibres. The results demonstrate a remarkable reduction in processing time of 233% for the fibre integration and a reduction of 56% for the width and 44% for the depth of the heat-affected zone compared to the initial setup.
ISSN:2073-4360
2073-4360
DOI:10.3390/polym15193975