Title: Flexible Fusion Process via Hot Powder Bed Compaction: Case for Additive Manufacturing of Topology Optimized Structures

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

DOI: 10.33599/nasampe/s.24.0111

Abstract: Traditional thermoplastic composite fabrication methods often rely on mold [1, 2], limiting manufacturing agility and efficiency. This research addresses the need for a high-performance, mold-independent approach for complex topological optimized components. We introduce the hot powder bed compaction (HPBC) technique, which combines fused filament fabrication (FFF) with a flexible compaction process. HPBC enables to creation of complex, high-performance thermoplastic composite parts, featuring topology-optimized geometry with tailored fiber orientation, without the need for part-specific tooling. This rapid fabrication approach is controlled by the time-temperature-pressure parameters to ensure inter-layer fusion without loss of the geometrical shape of the part. The structural rocker component was optimized for four load cases and printed with polyamide reinforced with short and long carbon fibers using the FFF process. Notably, HPBC results demonstrated improved mechanical performance compared to as-printed FFF. HPBC-treated coupon showed a 25.72% increase in flexural modulus (14.76 GPa) and a 27.77% increase in flexural strength (360 MPa). Moreover, the topologically optimized rocker exhibited a notable 30% increase in strength compared to the pristine counterpart, this improved performance was attributed to enhanced interlayer fusion and void infusion during reconsolidation, as demonstrated in micrographs. This research demonstrates that HPBC is a versatile and effective method for producing high-performance, complex-shaped, void-free composite parts with optimized fiber orientation, effectively addressing the limitations of traditional FFF.

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Conference: SAMPE 2024

Publication Date: 2024/05/20

SKU: TP24-0000000111

Pages: 16

Price: $32.00