This work explores a spatial printing method to fabricate continuous fiber-reinforced thermoplastic composites (CFRTPCs), which can achieve exceptional mechanical performance. For models giving complex 3D stress distribution under loads, typical planar-layer based fiber placement usually fails to provide sufficient reinforcement due to their orientations being constrained to planes. The effectiveness of fiber reinforcement could be maximized by using multi-axis additive manufacturing (MAAM) to better control the orientation of continuous fibers in 3D-printed composites. Here, we propose a computational approach to generate 3D toolpaths that satisfy two major reinforcement objectives: (1) following the maximal stress directions in critical regions and (2) connecting multiple load-bearing regions by continuous fibers. Principal stress lines are first extracted in an input solid model to identify critical regions. Curved layers aligned with maximal stresses in these critical regions are generated by computing an optimized scalar field and extracting its iso-surfaces. Then, topological analysis and operations are applied to each curved layer to generate a computational domain that preserves fiber continuity between load-bearing regions. Lastly, continuous fiber toolpaths aligned with maximal stresses are generated on each surface layer by computing an optimized scalar field and extracting its iso-curves. A hardware system with dual robotic arms is employed to conduct the physical MAAM tasks depositing polymer or fiber reinforced polymer composite materials by applying a force normal to the extrusion plane to aid consolidation. When comparing to planar-layer based printing results in tension, up to 644% failure load and 240% stiffness are observed on shapes fabricated by our spatial printing method. We demonstrate the versatility of our approach through various complex load cases which demonstrate their successful implementation of continuous fiber printing in 3D.

This paper reports the results of an international benchmark exercise on the measurement of fibre bed compaction behaviour. The aim was to identify aspects of the test method critical to obtain reliable results and to arrive at a recommended test procedure for fibre bed compaction measurements. A glass fibre 2/2 twill weave and a biaxial (±45°) glass fibre non-crimp fabric (NCF) were tested in dry and wet conditions. All participants used the same testing procedure but were allowed to use the testing frame, the fixture and sample geometry of their choice. The results showed a large scatter in the maximum compaction stress between participants at the given target thickness, with coefficients of variation ranging from 38% to 58%. Statistical analysis of data indicated that wetting of the specimen significantly affected the scatter in results for the woven fabric, but not for the NCF. This is related to the fibre mobility in the architectures in both fabrics. As isolating the effect of other test parameters on the results was not possible, no statistically significant effect of other test parameters could be proven. The high sensitivity of the recorded compaction pressure near the minimum specimen thickness to changes in specimen thickness suggests that small uncertainties in thickness can result in large variations in the maximum value of the compaction stress. Hence, it is suspected that the thickness measurement technique used may have an effect on the scatter.

This paper reports the results of an international benchmark exercise on the measurement of fibre bed compaction behaviour. The aim was to identify aspects of the test method critical to obtain reliable results and to arrive at a recommended test procedure for fibre bed compaction measurements. A glass fibre 2/2 twill weave and a biaxial (±45°) glass fibre non-crimp fabric (NCF) were tested in dry and wet conditions. All participants used the same testing procedure but were allowed to use the testing frame, the fixture and sample geometry of their choice. The results showed a large scatter in the maximum compaction stress between participants at the given target thickness, with coefficients of variation ranging from 38% to 58%. Statistical analysis of data indicated that wetting of the specimen significantly affected the scatter in results for the woven fabric, but not for the NCF. This is related to the fibre mobility in the architectures in both fabrics. As isolating the effect of other test parameters on the results was not possible, no statistically significant effect of other test parameters could be proven. The high sensitivity of the recorded compaction pressure near the minimum specimen thickness to changes in specimen thickness suggests that small uncertainties in thickness can result in large variations in the maximum value of the compaction stress. Hence, it is suspected that the thickness measurement technique used may have an effect on the scatter.

This paper reports the results of an international benchmark exercise on the measurement of fibre bed compaction behaviour. The aim was to identify aspects of the test method critical to obtain reliable results and to arrive at a recommended test procedure for fibre bed compaction measurements. A glass fibre 2/2 twill weave and a biaxial (±45°) glass fibre non-crimp fabric (NCF) were tested in dry and wet conditions. All participants used the same testing procedure but were allowed to use the testing frame, the fixture and sample geometry of their choice. The results showed a large scatter in the maximum compaction stress between participants at the given target thickness, with coefficients of variation ranging from 38% to 58%. Statistical analysis of data indicated that wetting of the specimen significantly affected the scatter in results for the woven fabric, but not for the NCF. This is related to the fibre mobility in the architectures in both fabrics. As isolating the effect of other test parameters on the results was not possible, no statistically significant effect of other test parameters could be proven. The high sensitivity of the recorded compaction pressure near the minimum specimen thickness to changes in specimen thickness suggests that small uncertainties in thickness can result in large variations in the maximum value of the compaction stress. Hence, it is suspected that the thickness measurement technique used may have an effect on the scatter.

The out-of-plane permeability of two glass fibre fabrics was measured by 26 institutions using silicone oil as a test fluid. Participants in this study were free to select the test procedure, specimen dimensions and data analysis method, provided that testing was carried out at three target fibre volume fractions, 46%, 50% and 54%. While results showed a variability of two orders of magnitude between participants, most values were within a significantly narrower band. A majority of participants used 1D saturated test method. A few selected 1D unsaturated and 3D unsaturated flow method which gave very similar results. Focusing on analysis of data and results of 1D saturated flow measurements, results are not conclusive, but they are consistent with number of layers in a specimen, fibre volume fraction, injection pressure and sealing of specimen edges all having an effect on the measured permeability. Specifying limits for these parameters is expected to result in reduced scatter in measured permeability.

The out-of-plane permeability of two glass fibre fabrics was measured by 26 institutions using silicone oil as a test fluid. Participants in this study were free to select the test procedure, specimen dimensions and data analysis method, provided that testing was carried out at three target fibre volume fractions, 46%, 50% and 54%. While results showed a variability of two orders of magnitude between participants, most values were within a significantly narrower band. A majority of participants used 1D saturated test method. A few selected 1D unsaturated and 3D unsaturated flow method which gave very similar results. Focusing on analysis of data and results of 1D saturated flow measurements, results are not conclusive, but they are consistent with number of layers in a specimen, fibre volume fraction, injection pressure and sealing of specimen edges all having an effect on the measured permeability. Specifying limits for these parameters is expected to result in reduced scatter in measured permeability.

Silica nanoparticles possessing three different diameters (23, 74 and 170 nm) were used to modify a piperidine-cured epoxy polymer. Fracture tests were performed and values of the toughness increased steadily as the concentration of silica nanoparticles was increased. However, no significant effects of particle size were found on the measured value of toughness. The toughening mechanisms were identified as (i) the formation of localised shear-band yielding in the epoxy matrix polymer which is initiated by the silica nanoparticles, and (ii) debonding of the silica nanoparticles followed by plastic void growth of the epoxy matrix polymer. These mechanisms, and hence the toughness of the epoxy polymers containing the silica nanoparticles, were modelled using the Hsieh et al. approach (Polymer 51, 2010, 6284-6294). However, it is noteworthy that previous modelling work has required the volume fraction of debonded silica particles to be measured from the fracture surfaces but in the present paper a new and more fundamental approach has been proposed. Here finite-element modelling has demonstrated that once one silica nanoparticle debonds then its nearest neighbours are shielded from the applied stress field, and hence may not debond. Statistical analysis showed that, for a good, i.e. random, dispersion of nanoparticles, each nanoparticle has six nearest neighbours, so only one in seven particles would be predicted to debond. This approach therefore predicts that only 14.3% of the nanoparticles present will debond, and this value is in excellent agreement with the value of 10-15% of those nanoparticles present debonding which was recorded via direct observations of the fracture surfaces. Further, this value of about 15% of silica nanoparticles particles present debonding has also been noted in other published studies, but has never been previously explained. The predictions from the modelling studies of the toughness of the various epoxy polymers containing the silica nanoparticles were compared with the measured fracture energies and the agreement was found to be good.

Silica nanoparticles possessing three different diameters (23, 74 and 170 nm) were used to modify a piperidine-cured epoxy polymer. Fracture tests were performed and values of the toughness increased steadily as the concentration of silica nanoparticles was increased. However, no significant effects of particle size were found on the measured value of toughness. The toughening mechanisms were identified as (i) the formation of localised shear-band yielding in the epoxy matrix polymer which is initiated by the silica nanoparticles, and (ii) debonding of the silica nanoparticles followed by plastic void growth of the epoxy matrix polymer. These mechanisms, and hence the toughness of the epoxy polymers containing the silica nanoparticles, were modelled using the Hsieh et al. approach (Polymer 51, 2010, 6284-6294). However, it is noteworthy that previous modelling work has required the volume fraction of debonded silica particles to be measured from the fracture surfaces but in the present paper a new and more fundamental approach has been proposed. Here finite-element modelling has demonstrated that once one silica nanoparticle debonds then its nearest neighbours are shielded from the applied stress field, and hence may not debond. Statistical analysis showed that, for a good, i.e. random, dispersion of nanoparticles, each nanoparticle has six nearest neighbours, so only one in seven particles would be predicted to debond. This approach therefore predicts that only 14.3% of the nanoparticles present will debond, and this value is in excellent agreement with the value of 10-15% of those nanoparticles present debonding which was recorded via direct observations of the fracture surfaces. Further, this value of about 15% of silica nanoparticles particles present debonding has also been noted in other published studies, but has never been previously explained. The predictions from the modelling studies of the toughness of the various epoxy polymers containing the silica nanoparticles were compared with the measured fracture energies and the agreement was found to be good.