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Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts

Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. Howe...

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Autores principales: Baranowski, Michael, Shao, Zijin, Spintzyk, Alexander, Kößler, Florian, Fleischer, Jürgen
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10575109/
https://www.ncbi.nlm.nih.gov/pubmed/37836023
http://dx.doi.org/10.3390/polym15193975
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author Baranowski, Michael
Shao, Zijin
Spintzyk, Alexander
Kößler, Florian
Fleischer, Jürgen
author_facet Baranowski, Michael
Shao, Zijin
Spintzyk, Alexander
Kößler, Florian
Fleischer, Jürgen
author_sort Baranowski, Michael
collection PubMed
description Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. However, the existing additive manufacturing processes for CCFRP parts have numerous disadvantages. Resin- and extrusion-based processes require time-consuming and costly post-processing to remove the support structures, severely restricting the design flexibility. Additionally, the production of small batches demands considerable effort. In contrast, laser sintering has emerged as a promising alternative in industry. It enables the creation of robust parts without needing support structures, offering efficiency and cost-effectiveness in producing single units or small batches. Utilising an innovative laser-sintering machine equipped with automated continuous fibre integration, this study aims to merge the benefits of laser-sintering technology with the advantages of continuous fibres. The paper provides an outline, using a finite element model in COMSOL Multiphysics, for simulating and identifying an optimised operating point range for the automated integration of continuous fibres. The results demonstrate a remarkable reduction in processing time of 233% for the fibre integration and a reduction of 56% for the width and 44% for the depth of the heat-affected zone compared to the initial setup.
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spelling pubmed-105751092023-10-14 Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts Baranowski, Michael Shao, Zijin Spintzyk, Alexander Kößler, Florian Fleischer, Jürgen Polymers (Basel) Article Additive manufacturing using continuous carbon-fibre-reinforced polymer (CCFRP) presents an opportunity to create high-strength parts suitable for aerospace, engineering, and other industries. Continuous fibres reinforce the load-bearing path, enhancing the mechanical properties of these parts. However, the existing additive manufacturing processes for CCFRP parts have numerous disadvantages. Resin- and extrusion-based processes require time-consuming and costly post-processing to remove the support structures, severely restricting the design flexibility. Additionally, the production of small batches demands considerable effort. In contrast, laser sintering has emerged as a promising alternative in industry. It enables the creation of robust parts without needing support structures, offering efficiency and cost-effectiveness in producing single units or small batches. Utilising an innovative laser-sintering machine equipped with automated continuous fibre integration, this study aims to merge the benefits of laser-sintering technology with the advantages of continuous fibres. The paper provides an outline, using a finite element model in COMSOL Multiphysics, for simulating and identifying an optimised operating point range for the automated integration of continuous fibres. The results demonstrate a remarkable reduction in processing time of 233% for the fibre integration and a reduction of 56% for the width and 44% for the depth of the heat-affected zone compared to the initial setup. MDPI 2023-10-03 /pmc/articles/PMC10575109/ /pubmed/37836023 http://dx.doi.org/10.3390/polym15193975 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Baranowski, Michael
Shao, Zijin
Spintzyk, Alexander
Kößler, Florian
Fleischer, Jürgen
Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title_full Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title_fullStr Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title_full_unstemmed Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title_short Simulation-Based Identification of Operating Point Range for a Novel Laser-Sintering Machine for Additive Manufacturing of Continuous Carbon-Fibre-Reinforced Polymer Parts
title_sort simulation-based identification of operating point range for a novel laser-sintering machine for additive manufacturing of continuous carbon-fibre-reinforced polymer parts
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10575109/
https://www.ncbi.nlm.nih.gov/pubmed/37836023
http://dx.doi.org/10.3390/polym15193975
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