The ambition of the proposed research is to bring together two important aspects of lightweight design and manufacturing: fused filament fabrication based additive manufacturing, and continuous fiber reinforced polymers for structural applications. In this way, the inherent advantages of the two components of the value chain (material and manufacturing) can be combined in order to obtain competitive structural components even lower production costs, in a flexible digital environment that allows rapid design changes in accordance with the requirements of a more and more dynamic market.
The project will focus on the development of new materials and technology for the specific Additive Manufacturing (AM) method of Fused Filament Fabrication (FFF) for high performance Continuous Fibers Reinforced Polymer (CFRP) parts that can be used under high lading conditions. The strategic goal of the research is to provide the frame (build the know-how, develop the technology, rise efficiency, asses properties and performances, investigate the domain of applicability and limitations, so) which would open the door of using the 3D printed CFRP composite parts as a more efficient alternative to traditionally manufactured composite components in specific industries like aerospace, automotive, wind energy, so.
This strategic target is motivated by the limitations that currently exist in the field of 3D printed polymer components, with respect to both available materials sets and technologies, regarding their usage in high performance and reliability applications. The current state of the art of the FFF technology for polymer materials corresponds to the usage of the sole polymer to produce the final part; at most, discontinuous fillers are used to improve the properties of the 3D printed part, which are still far lower compared to the potential properties of the CFRP based parts. The research into the methods of obtaining CFRP components as the output of the 3D printing process is only at its beginning, featuring a low degree of know-how and technological maturity; moreover, the development of these methods in Europe is almost inexistent.
This is why the operational objectives of the proposed research are focused on the development of new materials, products and methods in terms of the multiple and coupled aspects of: (i) multiphase constituent input materials for the AM process, (ii) processing technology for the input materials, and (iii) properties and performances of the final output CFRP composite 3D printed part. By addressing, understanding, and desirable solving the problems posed by each of the operational objectives, the aforementioned limitations can be released, and the strategic goal could be achieved.
The main impact of the project is expected at the levels of technology development and production of the value chain. Main stages of the current production chain for CFRP structural parts could be highly modified and simplified by the more flexible AM technology; there could be no more need for manufacturing of complex and expensive preforms, tooling, or resin infusion machines, which are required by current composite manufacturing technologies. Moreover, the more compact AM technology will have an impact on the needed infrastructure for production. These aspects, combined with a reduction of the scrap materials which is a characteristic attribute of any AM process, could have a positive environmental impact.
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