Additive Manufacturing of CFRP Composites Using Fused Deposition Modeling: Effects of Process Parameters

Fused deposition modeling (FDM) is one of the attractive additive manufacturing (AM) technologies for rapid prototyping with complex structures in a short timeframe. Thermoplastics are currently used as common feedstocks to fabricate prototypes in FDM process. However, FDM-fabricated pure thermoplastic parts cannot be used as load-bearing parts in the actual applications due to their limited tensile strength. Such condition could be improved by developing carbon fiber reinforced plastic (CFRP) composites using FDM for potential industrial end users. It is crucial that proper selections of FDM process parameters during fabricating CFRP composite parts could ensure the part quality and properties. However, the effects of FDM process parameters on the tensile properties of CFRP composites have not been explored. In this paper, CFRP composite specimens with 5 wt% carbon fiber content were fabricated using a FDM machine. Tensile testing was conducted to obtain the tensile properties. The effects of process parameters (including infill speed, nozzle temperature, and layer thickness) on the tensile properties of FDM-fabricated CFRP composite parts were investigated.