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Development of a print head for non-planar additive manufacturing of carbon fiber-reinforced polymers
Citation Link: https://doi.org/10.15480/882.15840
Publikationstyp
Journal Article
Date Issued
2025-08-01
Sprache
English
TORE-DOI
Volume
139
Issue
11-12
Start Page
5697
End Page
5714
Citation
The international journal of advanced manufacturing technology 139 (11/12): 5697–5714 (2025)
Publisher DOI
Scopus ID
Publisher
Springer
In order to realize the potential of high-performance lightweight parts manufactured using the combination of Fused Filament Fabrication (FFF) and Carbon Fiber Reinforced Polymers (CFRP), two main challenges have been identified for a print head design intended for load-oriented non-planar printing. To address these objectives of enabling dynamic layer height variation and fiber cutting, all while avoiding collisions in the printing system, this work presents the methodological development of a new specialized print head. By analyzing the process and taking the existing non-planar printing system into account, the relevant optimization parameters are identified and accurately defined. The methodological development is aligned with the VDI standard 2221 and includes a formal requirement analysis, parameter definition, and functional structure. The solution space is discussed and partial solutions are compared in detail, before the integration and final design are presented. The print head is physically realized, functionally verified by printing CFRP parts, and shown to fulfill all set requirements. Minor necessary changes during the manufacturing and construction of the system are discussed. Finally, the insight, definition, process analysis, and final version are employed to present a further optimized design with a concrete methodological outlook on enabling the load-oriented non-planar FFF of CFRP with this new highly optimized design.
Subjects
Carbon fiber-reinforced composites
Continuous
Cutting mechanism
Fused filament fabrication
Non-planar
Print head
DDC Class
620.1: Engineering Mechanics and Materials Science
Publication version
publishedVersion
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Name
s00170-025-16079-5.pdf
Type
Main Article
Size
2.64 MB
Format
Adobe PDF