Title: Part 1: The Efect of Defects on Traditional and 3D Printed Composite Performance – Specimen Development

Authors: Aaron M. Balles

DOI: 10.33599/nasampe/s.22.0809

Abstract: The use of Polymer Matrix Composites (PMC) has grown immensely over the past fifty years. Additive Manufacturing (AM) (3D printing) has also flourished and can be used to manufacture PMC. Both contain defects. It is unknown if common defects (air voids, resin rich areas, delaminations) affect AM PMCs the same as traditional PMCs. This work covers the development of appropriate fabrication methodologies and specimens that contain one of the three most common defects in composite components. Multiple fiber-reinforced FDM-type 3D printer filaments were evaluated to determine two of the strongest chopped fiber-reinforced nylon filaments. They and a graphite/epoxy unidirectional pre-preg were used to fabricate “Control” and “Defective” tensile and flexural specimens. Techniques were developed to ensure real voids in the pre-preg laminates. For the AM specimens, it was found that a properly set up print profile with drying and annealing had a larger effect on mechanical properties than the current defects. Experimental results are given in a sister paper “Part 2: The effect of Defects on Traditional and 3D Printed Composite Performance– Test Results.”

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Conference: SAMPE 2022

Publication Date: 2022/05/23

SKU: TP22-0000000809

Pages: 15

Price: $30.00