Title: Effect of Layer Height on Mechanical Performance of Additively Manufactured PC/CF with Integrated Fiber Reinforcement

Authors: Benjamin Steva, Roberto Lopez-Anido, Senthil Vel

DOI:

Abstract: Hybrid thermoplastic composites offer a promising route for lightweight, high-performance structures by combining the flexibility of additive manufacturing with the high strength and stiffness of continuous fiber reinforcement. In this study, hybrid composite parts were fabricated using a polymer extrusion-based large-format additive manufacturing (LFAM) robotic system integrated with an automated tape-layup process. Polycarbonate (PC), an amorphous thermoplastic known for its toughness and durability, was selected as the matrix material for both the LFAM pellets and the continuous fiber tapes. The LFAM pellets were reinforced with short carbon fibers, while continuous, unidirectional carbon fibers were embedded within tapes to achieve enhanced stiffness, strength and control the coefficient of thermal expansion (CTE). A key process parameter investigated was the bead, or layer height, during LFAM deposition, which directly influences interlayer bonding, CTE, and overall mechanical performance. Experimental characterization was conducted to evaluate the effect of varying layer height.

References: [1] “CW, ATLAM combines composite tape laying, large-scale thermoplastic 3D printing in one printhead.” [2] M. Feuchtgruber et al., “Using carbon fiber tape to tailor the coefficient of thermal expansion in 3D-Printed composite tooling,” Journal of Thermoplastic Composite Materials, vol. 38, no. 3, pp. 1257–1274, Mar. 2025, doi: 10.1177/08927057241264475. [3] S. R. Rajpurohit and H. K. Dave, “Analysis of tensile strength of a fused filament fabricated PLA part using an open-source 3D printer,” Int J Adv Manuf Technol, vol. 101, no. 5–8, pp. 1525–1536, Apr. 2019, doi: 10.1007/s00170-018-3047-x. [4] P. Striemann, L. Gerdes, D. Huelsbusch, M. Niedermeier, and F. Walther, “Interlayer Bonding Capability of Additively Manufactured Polymer Structures under High Strain Rate Tensile and Shear Loading,” Polymers, vol. 13, no. 8, p. 1301, Apr. 2021, doi: 10.3390/polym13081301. [5] B. M. Tymrak, M. Kreiger, and J. M. Pearce, “Mechanical properties of components fabricated with open-source 3-D printers under realistic environmental conditions,” Materials & Design, vol. 58, pp. 242–246, Jun. 2014, doi: 10.1016/j.matdes.2014.02.038. [6] J. L. Colón Quintana, L. Slattery, J. Pinkham, J. Keaton, R. A. Lopez-Anido, and K. Sharp, “Effects of Fiber Orientation on the Coefficient of Thermal Expansion of Fiber-Filled Polymer Systems in Large Format Polymer Extrusion-Based Additive Manufacturing,” Materials, vol. 15, no. 8, p. 2764, Apr. 2022, doi: 10.3390/ma15082764. [7] J. F. Keaton, “Investigating the Effect of Bead Geometry on Fiber Orientation and Thermomechanical Properties for Large-Format Extrusion-Based Additive Manufacturing,” ADDITIVE MANUFACTURING.

Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 46

Pages: 12

Price: $24.00