Mechanical Properties of Continuous Kevlar Fiber Reinforced Composites Fabricated by Fused Deposition Modeling Process

Additive Manufacturing (AM) is a promising technology because of the capability of fabricating complex freeform structures. Due to the rapid developing of AM techniques, the applications of AM are no longer limited to rapid prototyping. Functional parts can be directly fabricated by AM to satisfy given design requirements. Fused Deposition Modeling (FDM), one of the most widely used AM technique, has recently been modified to print continuous fiber reinforced thermoplastic materials. This research conducted experiments to understand the tensile property of 3D printed fiber reinforced composite materials. The fiber orientation, the volume fraction, and the position of fibers are considered in this study. The elastic modulus, yield strength, and the ultimate tensile strength have been calculated based on experimental results. Design guidelines for 3d printed continuous fibers are presented in this paper for designers to develop innovative products. Furthermore, some limitations of current FDM process in the fabrication of fiber reinforced composites are also discussed.