Batch production and fused filament fabrication of highly aligned discontinuous fibre thermoplastic filaments

Fused filament fabrication (FFF), which is a thermoplastic layer-by-layer additive manufacturing technique, called as 3D printing, can quickly build complex geometries, reducing design limitations and production costs of conventional manufacturing methods. Using a fibrous reinforcement strengthens the thermoplastic matrix, allowing FFF to be used in more structural complex-shape small-size applications in engineering. Aligned discontinuous fibre composites (ADFRC) incorporate a high-performance reinforcement architecture that, owing to a sufficient fibre length and high level of alignment, results in mechanical performance comparable to those of continuous fibre composites. Moreover, it can offer higher formability and, fewer manufacturing defects. In this paper, ADFRC preforms, produced with the High Performance Discontinuous Fibre (HiPerDiF) technology, were impregnated with poly(L-lactic acid) (PLA) and then reshaped to a circular-shaped 3D printing filament using a customised manual moulding and pultrusion method. Two different mould types were compared to maximise the filament quality and reduce the amount of trapped voids. The printability of the circular filaments was investigated by varying three parameters: deposition speed, processing temperature, and layer thickness. Finally, the tensile properties of samples from each manufacturing step: moulded, filament, single raster printed, and full height rectangular part, were investigated. Overall, the HiPerDiF-PLA filament can be printed using an 3D printer. Although the tensile properties of filament in each stage reduced as the result of the shape transformation process, the deposited layer of HiPerDiF-PLA part has greater stiffness and strength than other PLA composite materials. At this stage of technology development, the material has lower mechanical performance yet than the nylon continuous fibre composites printed with commercially available machines. However, there are clear routes forward for the improved performance of the HiPerDiF FFF printed filaments.

Automated summary

Fused filament fabrication (FFF) technology can be used to print complex geometries. The use of fibrous reinforcement strengthens the material's mechanical performance, and HiPerDiF-PLA filament has potential in 3D printing.