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The hybrid printing project aims to enhance the mechanical properties of manufactured parts in the automotive and aerospace sectors through the combination of short and long carbon fibers. In the automotive and aerospace sectors, the adoption of carbon fiber composites is due to their high strength and lightness, which enhance the efficiency and performance of vehicles and aircraft, while also enabling safer and more aerodynamic designs. This study used pultruded continuous fibers reinforced with polycarbonate (PC) and discontinuous fibers from PC pellets using Extrusion Deposition Additive Manufacturing (EDAM). The goal is to integrate these parts with new functionalities derived from the diverse material properties employed. A hybrid printing process was developed at the Composite Manufacturing and Simulation Center (CMSC). This process incorporates continuous fibers to provide structural rigidity and discontinuous fibers that enable the creation of complex geometries, despite limitations in typical mechanical properties of commercial additive manufacturing materials. The Composite Additive Manufacturing Research Instrument (CAMRI) printer, originally designed for pellet extrusion of discontinuous fibers, was adapted with a co-extrusion nozzle and continuous fiber feeding system, effectively enabling the fabrication of parts integrated with both types of fibers in this study. Keywords: Hybrid Printing; Continuous and Discontinuous Fibers; Carbon Fibers; Mechanical Engineering; 3D Printing

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Purdue University / 2024

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Arm Author