Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments.

Fused Deposition Modeling (FDM) is a widely used additive manufacturing technology for fabrication of complex geometric parts using thermoplastic polymers. The quality issues and inferior properties of fabricated parts limited this process to manufacture parts for industrial level applications. Reinforcing the polymer with nanoparticles, short fibers or continuous fibers improve mechanical, thermal and electrical properties compared to the neat polymer. Several works have been carried out since last two decades to print quality products through FDM by using composite materials. The success of expanding this technique to industrial applications depends on the preparation of printable composite feedstock filament and printing without defects. This article reviews the challenges involved in the preparation of composite feedstock filaments and printing issues during the printing of nano composites, short and continuous fiber composites. The printing process of various thermoplastic composites ranging from amorphous to crystalline polymers is discussed. Also, detailed explanation is given about the analytical and numerical models used for simulating the FDM printing process and for estimating the mechanical properties of the printed parts. This critical review mainly helps the young researchers working in the area of processing of composite materials via 3D printing.

A critical review on the fused deposition modeling of thermoplastic polymer composites

This is an accepted manuscript of an article published by Elsevier in Additive Manufacturing on 02/10/2021, available online: https://doi.org/10.1016/j.addma.2021.102378 
The accepted version of the publication may differ from the final published version.

pdf/fused-deposition-modelling-current-status-methodology-3yz0bg1iim.pdf

Fused Deposition Modelling: Current Status, Methodology, Applications and Future Prospects

Fused deposition modeling (FDM) has been successfully applied to fabricating short fiber reinforced polymer composites parts. However, due to the intrinsically limited mechanical properties of matrix polymers, there is critical need to develop fiber reinforced high-performance thermoplastic composites for FDM-3D printing to expand engineering applications. In this work, the potential of FDM-3D printing short carbon fiber (CF) and glass fiber (GF) reinforced high-performance PEEK composites has been investigated. Composite filaments with fiber contents of 5 wt%, 10 wt% and 15 wt% were prepared using extrusion process and characterized by micromorphology observation; and thermal properties testing demonstrated its better thermal stability than pure PEEK. The performance evaluation of printed CF/GF-PEEK parts was focused, including mechanical properties, microstructure, surface quality and porosity. The results indicate that the addition of CF/GF to PEEK can significantly enhance the tensile and flexural strength at the cost of ductility. Lower fiber content of 5 wt% is conducive to increasing mechanical properties, improving surface quality and reducing porosity of printed CF/GF-PEEK. GF/PEEK has better interfacial bonding than CF/PEEK due to the different surface treatments on fibers. Furthermore, microstructure observation suggests that fibers aligned along the printing orientation can strengthen the properties, while pores lead to performance degradation of 3D printed CF/GF-PEEK.

Preparation of short CF/GF reinforced PEEK composite filaments and their comprehensive properties evaluation for FDM-3D printing

The mechanical testing and performance analysis of polymer-fibre composites prepared through the additive manufacturing

Fused deposition modeling (FDM) is a rapidly growing three-dimensional (3D) printing technology and has great potential in medicine. Polyether-ether-ketone (PEEK) is a biocompatible high-performance polymer, which is suitable to be used as an orthopedic/dental implant material. However, the mechanical properties and biocompatibility of FDM-printed PEEK and its composites are still not clear. In this study, FDM-printed pure PEEK and carbon fiber reinforced PEEK (CFR-PEEK) composite were successfully fabricated by FDM and characterized by mechanical tests. Moreover, the sample surfaces were modified with polishing and sandblasting methods to analyze the influence of surface roughness and topography on general biocompatibility (cytotoxicity) and cell adhesion. The results indicated that the printed CFR-PEEK samples had significantly higher general mechanical strengths than the printed pure PEEK (even though there was no statistical difference in compressive strength). Both PEEK and CFR-PEEK materials showed good biocompatibility with and without surface modification. Cell densities on the “as-printed” PEEK and the CFR-PEEK sample surfaces were significantly higher than on the corresponding polished and sandblasted samples. Therefore, the FDM-printed CFR-PEEK composite with proper mechanical strengths has potential as a biomaterial for bone grafting and tissue engineering applications.

https://www.mdpi.com/2077-0383/8/2/240/pdf

Carbon Fiber Reinforced PEEK Composites Based on 3D-Printing Technology for Orthopedic and Dental Applications.

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Carbon Fiber Reinforced PEEK Composites Based on 3D-Printing Technology for Orthopedic and Dental Applications.