Introduction to Additive Manufacturing for Thermoplastic Composites

Additive manufacturing (AM) is a family of several joining processes that enables the layer-by-layer fabrication of structures featuring complex geometries that usually cannot be achieved using conventional manufacturing methods (e.g., injection molding, machining). AM offers numerous benefits and drives innovation through design freedom, reliability, and cost-effectiveness. It enables the rapid, tool-free fabrication of high-performance, multifunctional, lightweight, and sustainable composite materials and structures. The AM of composites allows for the creation of parts that are both complex in shape and that exhibit high specific strength and stiffness.

This webinar presents an introduction to AM technologies with a focus on the material-extrusion 3D printing processes for thermoplastic composites reinforced with short (e.g., chopped) and continuous carbon fibers. The three main material-extrusion-based 3D printing processes discussed are the Fused Filament Fabrication (FFF), the Fused Granulate Fabrication (FGF) and the Continuous Fiber Fabrication (CFF). For each process, a few examples of commercial and industrial 3D printers and their main characteristics and limitations are mentioned. More advanced AM methods featuring non-planar, large-scale manufacturing, high productivity, multi-material printing are introduced. Two case studies are described with emphasis on the printer components, the processing challenges and some solutions investigated so far. Some examples of industrial applications of the AM of composites are briefly mentioned to conclude.

Presented by:
Daniel Therriault
Department of Mechanical Engineering
Polytechnique Montréal