Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts
Additive manufacturing of continuous carbon fibre-reinforced polymer (CCFRP) parts enables the production of high-strength parts for aerospace, engineering and other industries. Continuous fibres allow for parts to be reinforced along the load path, multiplying their mechanical properties. However,...
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| Format: | Article |
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MDPI AG
2023-04-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/13/9/5351 |
| _version_ | 1797603101717299200 |
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| author | Michael Baranowski Lukas Völger Marco Friedmann Jürgen Fleischer |
| author_facet | Michael Baranowski Lukas Völger Marco Friedmann Jürgen Fleischer |
| author_sort | Michael Baranowski |
| collection | DOAJ |
| description | Additive manufacturing of continuous carbon fibre-reinforced polymer (CCFRP) parts enables the production of high-strength parts for aerospace, engineering and other industries. Continuous fibres allow for parts to be reinforced along the load path, multiplying their mechanical properties. However, current additive manufacturing processes for producing CCFRP parts do not optimally meet the requirements of the matrix. With resin- and extrusion-based processes, the time-consuming and costly post-processing required to remove support structures severely limits design freedom, and producing small batches requires increased effort. In contrast, laser sintering has proven to be a promising alternative in an industrial environment, allowing the production of robust parts without support structures in a time-efficient and economical manner for single and small-batch production. Based on a novel laser-sintering machine with the automated integration of continuous fibres, a combination of the advantages of the laser-sintering process and the advantages of continuous fibres is to be achieved. This paper describes an experimental analysis and optimisation of this laser-sintering machine using design of experiments. The processing time for fibre integration could be reduced by a factor of three compared to the initial state. |
| first_indexed | 2024-03-11T04:24:40Z |
| format | Article |
| id | doaj.art-ec27fb8c930949ffb2dc7c31f05e93d3 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-11T04:24:40Z |
| publishDate | 2023-04-01 |
| publisher | MDPI AG |
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| spelling | doaj.art-ec27fb8c930949ffb2dc7c31f05e93d32023-11-17T22:32:48ZengMDPI AGApplied Sciences2076-34172023-04-01139535110.3390/app13095351Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer PartsMichael Baranowski0Lukas Völger1Marco Friedmann2Jürgen Fleischer3Institute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstaße 12, 76131 Karlsruhe, GermanyInstitute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstaße 12, 76131 Karlsruhe, GermanyInstitute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstaße 12, 76131 Karlsruhe, GermanyInstitute of Production Science, Faculty of Mechanical Engineering, Karlsruhe Institute of Technology (KIT), Kaiserstaße 12, 76131 Karlsruhe, GermanyAdditive manufacturing of continuous carbon fibre-reinforced polymer (CCFRP) parts enables the production of high-strength parts for aerospace, engineering and other industries. Continuous fibres allow for parts to be reinforced along the load path, multiplying their mechanical properties. However, current additive manufacturing processes for producing CCFRP parts do not optimally meet the requirements of the matrix. With resin- and extrusion-based processes, the time-consuming and costly post-processing required to remove support structures severely limits design freedom, and producing small batches requires increased effort. In contrast, laser sintering has proven to be a promising alternative in an industrial environment, allowing the production of robust parts without support structures in a time-efficient and economical manner for single and small-batch production. Based on a novel laser-sintering machine with the automated integration of continuous fibres, a combination of the advantages of the laser-sintering process and the advantages of continuous fibres is to be achieved. This paper describes an experimental analysis and optimisation of this laser-sintering machine using design of experiments. The processing time for fibre integration could be reduced by a factor of three compared to the initial state.https://www.mdpi.com/2076-3417/13/9/5351laser sintering (LS)continuous carbon fibre-reinforced polymer parts (CCFRPs)fibre integration unitheat affected zonesplit-plot design (SPD)central composite design (CCD) |
| spellingShingle | Michael Baranowski Lukas Völger Marco Friedmann Jürgen Fleischer Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts Applied Sciences laser sintering (LS) continuous carbon fibre-reinforced polymer parts (CCFRPs) fibre integration unit heat affected zone split-plot design (SPD) central composite design (CCD) |
| title | Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts |
| title_full | Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts |
| title_fullStr | Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts |
| title_full_unstemmed | Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts |
| title_short | Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts |
| title_sort | experimental analysis and optimisation of a novel laser sintering process for additive manufacturing of continuous carbon fibre reinforced polymer parts |
| topic | laser sintering (LS) continuous carbon fibre-reinforced polymer parts (CCFRPs) fibre integration unit heat affected zone split-plot design (SPD) central composite design (CCD) |
| url | https://www.mdpi.com/2076-3417/13/9/5351 |
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