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UWE Bristol Engineering showcase 2015

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Nicola Reed<br />

BEng Aerospace <strong>Engineering</strong> (Manufacturing)<br />

Enhancement of Mechanical Properties of Additive Manufacturing<br />

Materials<br />

Additive Manufacturing (also known as AM) is a layering fabrication process which uses many different materials to build a wide variety of products across<br />

many industries. This project will investigate the theory and practise of using fibres (glass and carbon fibre) to reinforce structures printed using AM methods.<br />

Additive Manufacturing has quickly emerged as a technology of the future. The ability to ‘print’ objects layer by layer has become a fabrication method which<br />

60% of businesses (within the engineering and design sectors) are currently utilising (Hammond, 2014). It is because of this that this project investigates<br />

whether it is possible to produce fibrous printed structures by using additive manufacturing methods, thus increasing the market for these machines. With AM<br />

manufacturing technologies becoming more common within businesses and the home, increased resources are being invested in the research and<br />

development of 3D printers to ensure that the technology continues to progress and become accessible and affordable for all.<br />

Project Supervisor<br />

Dr David Richardson<br />

Project summary<br />

This project investigates whether the addition<br />

of fiber reinforcement affects the mechanical<br />

properties of an additively manufactured<br />

structure, also whether the build orientation<br />

of a 3D printed sample affects these key<br />

properties.<br />

Research<br />

Thorough research was carried out into all aspects of 3D printing and a<br />

comprehensive literature review was written. It was at this point in the<br />

project it was decided that it would not be possible to combine the fibrous<br />

reinforcement with the 3D printing filament. This was due to the logistics of<br />

combining them in an evenly dispersed way. The machine being used for this<br />

investigation utilizes the Fused Deposition Modelling method, the fibers may<br />

also have caused issue with ‘pulling out’ of the matrix polymer material;<br />

another reason why this was not feasible within this investigation.<br />

At this point in the project it was decided that Epoxy resin samples would be<br />

manufactured, and the fibers added to the mixture – these would then be<br />

tested to determine the affect on the Mechanical properties of the<br />

additional reinforcement.<br />

It was also decided that different build orientations would be investigated<br />

and samples be tested to determine whether this parameter affects the<br />

properties of the printed sample. The below diagram shows the FDM<br />

machine used for this investigation.<br />

Method<br />

Using the relevant ISO a test plan was created, CAD model drawn and .STL file<br />

sent to the technicians to be printed. Following the successful manufacture of<br />

the samples in each build direction they were then received for testing. The<br />

machine used for testing can be seen below.<br />

Each sample was measured and tested.<br />

(this included the samples<br />

manufactured from Epoxy resin).<br />

The results of the testing concluded<br />

that the addition of the fibers improved<br />

the Mechanical properties (Young’s<br />

Modulus and Yield Strength) of the<br />

samples. It can also be concluded that<br />

the build direction does also affect the<br />

Mechanical properties of a sample.<br />

Further testing needs to be carried out<br />

to determine whether it is<br />

possible to combine the 3D printed<br />

Polymer material with the fibrous<br />

reinforcement.<br />

Project Objectives<br />

• Investigate how reinforcement can affect<br />

Epoxy mold samples<br />

• Deign and manufacture test samples to be<br />

printed on an Additive Manufacturing<br />

machine<br />

• Investigate the logistics of the addition of<br />

fiber reinforcement to 3D printer polymer<br />

material<br />

• Research the effect of the build orientation<br />

on the Mechanical properties of 3D printed<br />

materials<br />

• Tensile test the manufactured samples and<br />

record the resultant Mechanical properties<br />

Project Conclusion<br />

The addition of fibers to the epoxy samples<br />

increased both the Yield Strength and the<br />

Young’s Modulus. From this it can be<br />

concluded that the addition of fibers to a 3D<br />

printed polymer material would therefore<br />

enhance the Mechanical properties of an<br />

Additively Manufactured printed sample. It<br />

can also be concluded that the build<br />

orientation does affect the Mechanical<br />

properties of a 3D printed sample.

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