Fused filament fabrication of structural continuous carbon fiber thermoplastic composites

Conventional manufacturing of carbon fiber composite structures are often limited to simple geometries. Often, these composite fabrication techniques are used because contemporary methods, such as additive manufacturing (AM), are restricted to nano- and micro- scale reinforcements that do not exhibit the needed characteristics for structural applications. Additionally, there is an emphasis on thermosetting polymer matrices, as they are often used with carbon fiber composite structures, which are not highly compatible with the most popular AM technique, Fused Filament Fabrication (FFF). FFF primarily uses thermoplastic feedstock and is easily accessible by a vast variety of users. Furthermore, high-performance thermoplastics, such as poly ether ether ketone (PEEK), are resistant to extreme temperatures, chemically inert, and provide impressive mechanical strength.
This study aims to investigate the materials and processing of high-performance thermoplastic composites with continuous carbon fiber and nanoparticle reinforcements through means of fused filament fabrication, which offers a cost-effective solution to rapidly produce complex composite components. Through means of melt compounding and co-extrusion of continuous fiber filaments, additively manufactured, highly custom composite structures with unique properties are possible. With the addition of nanoparticles, such as carbon nanotubes (CNT), control of the morphological characteristics of the matrix material is achievable and additional reinforcement properties for increased tensile strength can be obtained. The resulting synergistic effects of continuous fiber composites manufactured via FFF offer a means for an accessible, rapid production of aerospace and automotive components.