Additive Manufacturing of Continuous Fibre Reinforced Polymer Composites Through Combination of Rapid Tow Shearing Deposition and Layer-by-Layer Curing

Abstract

This research aims to explore the advancement of an additive manufacturing technique for continuous fibre reinforced polymer (CFRP) composites by combining Rapid Tow Shearing (RTS) deposition with Layer-by-Layer (LbL) curing. This approach aims to address the challenges associated with conventional manufacturing of thermoset composites, such as extended curing cycles, temperature spikes, and defects arising from inconsistent curing. A Finite Element (FE) model was developed to simulate the thermal response of CFRP composites during the LbL-RTS process. Validation results demonstrated a strong correlation between the model predictions and experimental data, confirming the accuracy of the developed model. The integrated process envelope was investigated through a set of simulations. Findings from the study illustrate that the LbL-RTS process can effectively reduce temperature overshoot by up to 30°C compared to traditional monolithic curing methods, thereby helping maintain material integrity and minimise the risk of thermal degradation. In addition, a parametric analysis is conducted to uncover the impact of varying deposition speeds on temperature profiles. The study found that for every 0.5 mm/s increase in deposition speed, the temperature overshoot rises by 5°C. However, higher deposition speeds at 100% IR power reduce temperature spikes by 6°C. Future improvements include adding mechanical properties in FE to predict and understand mechanical behaviour. Developing a deposition head that combines RTS benefits with an embedded flash lamp for irradiating tapes during deposition. Mechanical tests such as peel ply or Interlaminar Shear Strength on LbL-RTS samples would assess the interfacial and structural integrity of the produced component.