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- Title
Coupling design and fabrication of continuous carbon fiber-reinforced composite structures using two-material topology optimization and additive manufacturing.
- Authors
Ho, Thuan N.-T.; Nguyen, Son H.; Le, Van Thao; Hoang, Tien-Dat
- Abstract
This study presents an integration of the level set-based two-material topology optimization method and the additive manufacturing technique for the design and fabrication of continuous carbon fiber (CCF)-reinforced composite structures. Firstly, optimal configurations of the resin material and fiber reinforcement are obtained to maximize the structural stiffness under desired volume constraints using the two-material topological optimization. After that, the level set-based cutting mesh method and triangulation scheme are employed to interpret these topological designs into stereolithography (STL) models with clear structural boundaries for the manufacturing. A customized pre-processing strategy is used to accurately determine the fiber placement regions from the optimal designs. Topological results are then fabricated using the CCF-based 3D printing method with prepreg carbon fibers. Subsequently, the performance of printed CCF-reinforced composite structures is investigated, using different resin materials: polylactic acid (PLA) and polyamide 12 with 10% carbon fiber (PA12_10CF). Experimental results indicate a significant increase in stiffness and strength of composite structures with fiber reinforcements for all resin materials, with an increase of 315% for PLA and 234% for PA12_10CF. Additionally, the CCF-reinforced composite structures made of PA12_10CF exhibit superior stiffness compared to those made of PLA with a double increment. The microstructural characteristics of damaged regions are examined using scanning electron microscope (SEM) images, which provide valuable insights into the behavior of resin and fiber materials.
- Publication
International Journal of Advanced Manufacturing Technology, 2024, Vol 130, Issue 9/10, p4277
- ISSN
0268-3768
- Publication type
Article
- DOI
10.1007/s00170-023-12913-w