Title: Applicability of Additively Manufactured Fiber-Reinforced Thermoplastic Composite Mold for Thermoplastic Composite Thermoforming Process

Authors: Hanhyun kwak, Sung Jun Choi, Eduardo Barocio, Garam Kim

DOI: 10.33599/nasampe/s.25.0124

Abstract: Thermoforming is a widely used manufacturing process that traditionally relies on metal molds to shape thermoplastic polymer sheets. However, the high costs and long lead times associated with metal mold fabrication present significant challenges. This research explores the use of additively manufactured carbon fiber-reinforced Polyphenylene Sulfide (PPS) composites as an innovative substitute for metal molds in the thermoforming process, specifically focusing on the molding of fiber-reinforced Polyamide 6 (PA6) and Polyetherketoneketone (PEKK) composite laminates. A key focus of this study is evaluating the performance of 3D-printed thermoplastic composite molds, assessing their thermal performance and durability when exposed to elevated temperatures during the thermoforming process. Experiments were conducted to measure temperature distribution across the mold using a thermal camera. In addition, digital image correlation (DIC) technology was employed to investigate mold deformation during and after the forming cycles. Digital Image Correlation (DIC) is a non – contact optical method for measuring surface displacement and strain. It tracks speckle pattern movement on a specimen to determine deformation during forming. To enhance mold protection, a thermal barrier made of an aluminum layer was installed between the 3D-printed mold and the formed composite laminate to dissipate heat during the forming process. The results reveal the impact of the thermal barrier on mold stability and deformation, demonstrating that composite molds offer a viable alternative to metal molds for thermoforming. This research highlights the potential for cost-effective, efficient, and sustainable mold solutions across multiple industries, while maintaining the necessary performance and technical standards.

References: [1] Hale, Justin. “Boeing 787 from the ground up.” AERO Magazine Q4 (06), Boeing Company (2006): 16-23. [2] Gibson, Ronald F. Principals of Composite Material Mechanics. Boca Raton, FL, United States: Taylor & Francis, 2016. [3] Kim, H.-G. & Wiebe, R. "Numerical investigation of stress states in buckled laminated composite plates under dynamic loading." Composite Structures 235 (2020): 111743. [4] Justusson, B. & Schaefer, J. D. "Development of Analytical Capabilities for Through Thickness Composite Structure Design and Substantiation." In AIAA SCITECH 2022 Forum, p. 1780. 2022. [5] Ozborn, D. A., Black, J. W., Huberty, W., Christopher B. & Kim, H.-G. "Experimental multi-scale characterization of mode-II interlaminar fracture in geometrically scaled stitched and unstitched resin-infused composites." Proceedings of 2024 AIAA SciTech Forum and Exposition. Orlando, Florida, January 8-12, 2024. American Institute of Aeronautics and Astronautics. pp. 2083. [6] Davidson, B. D. & Sun, X. "Geometry and data reduction recommendations for a standardized end notched flexure test for unidirectional composites." Journal of ASTM International 3, no. 9 (2006): JAI100285. [7] Davidson, Barry D. "Towards an ASTM standardized test for determining G IIc of unidirectional laminated polymeric matrix composites." In 21st Technical Conference of the American Society for Composites 2006, pp. 49-66. 2006. [8] ASTM Standard D7905/D7905M-19e1, "Standard Test Method for Determination of the Mode II Interlaminar Fracture Toughness of Unidirectional Fiber-Reinforced Polymer Matrix Composites" ASTM International, West Conshohocken, PA, 2019, DOI: 10.1520/ D7905/D7905M-19e1, www.astm.org. [9] Salviato, M., Kirane, K., Bažant, Z. P. & Cusatis, G. "Mode I and II interlaminar fracture in laminated composites: a size effect study." Journal of Applied Mechanics 86, no. 9 (2019): 091008. [10] Bažant, Zdeněk P. "Snapback instability at crack ligament tearing and its implication for fracture micromechanics." Cement and Concrete Research 17, no. 6 (1987): 951-967. [11] Rice, James R. “A path independent integral and the approximate analysis of strain concentration by notches and cracks.” Journal of Applied Mechanics. 35(2) (1968): 379386. [12] Kim, H.-G. & Wiebe, R. "Experimental and numerical investigation of nonlinear dynamics and snap-through boundaries of post-buckled laminated composite plates." Journal of Sound and Vibration 439 (2019): 362-387. [13] Bažant, Zdeněk P. "Size effect in blunt fracture: concrete, rock, metal." Journal of Engineering Mechanics 110, no. 4 (1984): 518-535. [14] Dassault Systèmes Simulia Corp., Johnston, RI, United States, Abaqus/CAE 2022 (2021).

Conference: SAMPE 2025

Publication Date: 2025/05/19

SKU: TP25-0000000124

Pages: 13

Price: $26.00