Title: Investigation of Hot Powder Bed Compaction for Enhanced Fusion Bonding in Additive Manufacturing of Composite Component

Authors: Jimesh D. Bhagatjia, Gonzalo Fernandeza, Theodore Osunigaa, Oleksandr G. Kravchenkoa

DOI: 10.33599/nasampe/c.24.0353

Abstract: Conventional thermoplastic composite fabrication methods rely on molds, which often hinder manufacturing agility and efficiency. This research aims to address the demand for a mold-independent approach for fabricating high-performance components. We present the hot powder bed compaction (HPBC) technique, which combines Fused Filament Fabrication (FFF) with a compaction process. This fabrication approach allows to control time-temperature-pressure parameters to ensure inter-layer fusion while preserving the geometric shape of the part. This process enables the fabrication of high-performance thermoplastic composite parts, incorporating topology-optimized geometry and tailored fiber orientation, without the need for part-specific mold. The effectiveness of the HPBC was demonstrated through tensile testing until failure of dog-bone coupons and dovetail joint, fabricated from short, discontinuous carbon fibers (SCF) filament. HPBC treated coupon with dovetail maintains the elastic modulus (2.73 GPa), strength (52.63 MPa) and enhance interlayer fusion as demonstrated in micrographs. This research demonstrates a versatile and effective post-printing technique for producing high-performance, void-free composite parts with optimized fiber orientation, effectively addressing the limitations of traditional FFF.

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Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000353

Pages: 11

Price: $22.00