Tensile properties and failure behavior of chopped and continuous carbon fiber composites produced by additive manufacturing

The use of additive manufacturing (AM) is rapidly expanding in many industries mostly because of the flexibility to manufacture complex geometries. Recently, a family of technologies that produce fiber reinforced components has been introduced, widening the options available to designers. AM fiber reinforced composites are characterized by the fact that process related parameters such as the amount of reinforcement fiber, or printing architecture, significantly affect the tensile properties of final parts. To find optimal structures using new AM technologies, guidelines for the design of 3D printed composite parts are needed. This paper presents an evaluation of the effects that different geometric parameters have on the tensile properties of 3D printed composites manufactured by fused filament fabrication (FFF) out of continuous and chopped carbon fiber reinforcement. Parameters such as infill density and infill patterns of chopped composite material, as well as fiber volume fraction and printing architecture of continuous fiber reinforcement (CFR) composites are varied. The effect of the location of the initial deposit point of reinforcement fibers on the tensile properties of the test specimens is studied. Also, the effect that the fiber deposition pattern has on tensile performance is quantified. Considering the geometric parameters that were studied, a variation of the Rule of Mixtures (ROM) that provides a way to estimate the elastic modulus of a 3D printed composite is proposed. Findings may be used by designers to define the best construction parameters for 3D printed composite parts.