Additive manufacturing (AM), also known as 3D printing, is an emerging and potentially revolutionary technology aimed at small volume manufacturing for highly customized applications, e.g. aerospace, medical devices, and replacement parts. However, the processing technology still requires development before it can be used to manufacture final parts beyond mere prototypes. The AM of continuous fiber reinforced thermoplastic composites, in particular, presents its own set of challenges compared to processes that work with neat polymers, metals, and ceramics due to the anisotropy of the material.
Continuous Lattice Fabrication (CLF), a patented technology developed at the ETH Zurich, is the first to present a truly 3D fabrication process for composite material not based on layer by layer build ups, capable of fabricating out-of-plane reinforcements.
Additive manufacturing (AM), also known as 3D printing, is an emerging and potentially revolutionary technology aimed at small volume manufacturing for highly customized applications, e.g. aerospace, medical devices, and replacement parts. However, the processing technology still requires development before it can be used to manufacture final parts beyond mere prototypes. The AM of continuous fiber reinforced thermoplastic composites, in particular, presents its own set of challenges compared to processes that work with neat polymers, metals, and ceramics due to the anisotropy of the material. Continuous Lattice Fabrication (CLF), a patented technology developed at the ETH Zurich, is the first to present a truly 3D fabrication process for composite material not based on layer by layer build ups, capable of fabricating out-of-plane reinforcements.
The objective of this work is the continuation of a previous thesis which was focused on the numerical modelling of the material characteristics, including temperature transient material behaviour. The scope of this work includes the modelling of the deconsolidation behaviour of the extrudate (internal loads) under thermoforming conditions and the integration of the crystallisation conditions as well as the respective experimental validation.
Work Breakdown:
- Integration of a stationary temperature field to speed up computation time.
- Integration of residual stresses to simulate the deconsolidation behaviour of the extrudate after leaving the heated extrusion nozzle.
- Integration of crystallisation effects to simulate the state of crystallinity after extrusion.
- Experimental tests to validate the simulated material behaviour.
The objective of this work is the continuation of a previous thesis which was focused on the numerical modelling of the material characteristics, including temperature transient material behaviour. The scope of this work includes the modelling of the deconsolidation behaviour of the extrudate (internal loads) under thermoforming conditions and the integration of the crystallisation conditions as well as the respective experimental validation.
Work Breakdown: - Integration of a stationary temperature field to speed up computation time. - Integration of residual stresses to simulate the deconsolidation behaviour of the extrudate after leaving the heated extrusion nozzle. - Integration of crystallisation effects to simulate the state of crystallinity after extrusion. - Experimental tests to validate the simulated material behaviour.
ETH Zurich,
Martin Eichenhofer,
CLA E32.2,
Tannenstrasse 3,
8092 Zurich,
Phone: +41 44 633 92 83,
martieic@ethz.ch,
www.structures.ethz.ch
ETH Zurich, Martin Eichenhofer, CLA E32.2, Tannenstrasse 3, 8092 Zurich, Phone: +41 44 633 92 83, martieic@ethz.ch, www.structures.ethz.ch