Evaluation of the impact performance and energy absorption capabilities of 3D printed composites

Abstract

Purpose

Composites 3D printing has the potential to replace the conventional manufacturing processes for engineering applications because it allows for the manufacturing of complex shapes with the possibility of reducing the manufacturing cost. This paper aims to analyse the performance of 3D printed fibre reinforced polymer composites to investigate the energy absorption capabilities and the residual properties before and after impact.

Design/methodology/approach

Various composites composed of carbon fibres and Kevlar fibres embedded into both Onyx and nylon matrix were printed using Markforged-Two 3D printers. Specimens with different fibre orientations and fibre volume fractions (Vf) were printed. A drop-weight impact test was performed at energies of 2, 5, 8 and 10 J. Flexural testing was performed to evaluate the flexural strength, flexural modulus and absorbed energy under bending (AEUB) before and after impact. Additionally, 3D printed carbon fibre composites were tested at two different temperatures to study their behaviour under room and sub-ambient temperatures. Failure modes were investigated using optical and high depth of field microscopes for all 3D printed composite samples.

Findings

Kevlar/nylon composites with a unidirectional lay-up and 50% Vf exhibited the most prominent results for AEUB at room temperature. The high-Vf carbon fibre composite showed the highest ultimate strength and modulus and performed best at both temperature regimes.

Originality/value

The work, findings and testing produced in this paper are entirely original with the objective to provide further understanding of 3D printed composites and its potential for use in many applications.

Citation

Swart, R., Korkees, F., Dorrington, P. and Thurman, J. (2022), "Evaluation of the impact performance and energy absorption capabilities of 3D printed composites", Rapid Prototyping Journal, Vol. 28 No. 9, pp. 1636-1654. https://doi.org/10.1108/RPJ-10-2021-0287