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Published in:
2025 | OriginalPaper | Chapter
15. 3D Printing and Its Applications for Composites (Additive Manufacturing)
Author : Bahram Farahmand
Published in: Fundamentals of Composites and Their Methods of Fabrications
Publisher: Springer Nature Switzerland
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Abstract
The chapter begins by introducing the fundamental principles of 3D printing, also known as additive manufacturing (AM), which involves creating physical parts from digital models by adding material layer by layer. This method contrasts with traditional subtractive manufacturing techniques, which involve removing material from a larger block. The text explores various AM processes, including powder bed fusion (PBF) and direct energy deposition (DED), each utilizing different materials and heat sources to build parts. The discussion covers the advantages and limitations of these processes, such as the ability to create complex geometries with high precision and the need for post-processing to achieve desired mechanical properties. The chapter also delves into the applications of AM in different industries, highlighting its potential in aerospace, automotive, and medical fields. It examines the use of composite materials, including carbon fiber and fiberglass, and the parameters influencing the mechanical properties of 3D-printed composites. The text provides a comprehensive overview of the challenges and opportunities in additive manufacturing, emphasizing the need for further research to improve material quality and reduce manufacturing costs. Additionally, it discusses the role of support structures, feeding systems, and the interaction between digital models and 3D printers in achieving high-quality, functional parts. The chapter concludes by exploring the future of 3D printing in composite manufacturing, highlighting its potential to revolutionize various industries by enabling the creation of customized, high-performance components.
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Abstract
This chapter explores the importance and impact of 3D printing technology, also known as Additive Manufacturing (AM), in composites manufacturing. As a revolutionary technique, 3D printing has gained significant demand for its ability to create complex and customized structures layer by layer. The chapter begins by providing an overview of the fundamental principles of 3D printing and the key technologies involved in additive manufacturing. Subsequently, it examines the unique advantages and challenges posed by 3D printing in the context of composite materials. Several available AM processes are discussed, utilizing laser or electron beams as the source of energy to create composite parts exactly as customers requested, based on computer-aided design (CAD). The discussion encompasses various aspects of 3D printing, including material selection (feedstock), printing processes, and the integration of reinforcing fibers into the matrix. The chapter reviews recent advancements in composite 3D printing techniques, such as powder bed fusion (PBF) and direct energy deposition (DED), both utilizing lasers as the source of energy. Several other 3D printing techniques are also discussed in detail, and the advantages and disadvantages of each method are presented. Additionally, this work explores the influence of process parameters on the mechanical properties, structural integrity, and overall performance of 3D-printed composites. The impact of residual stresses built into the part, as a result of high input heat, and the formation of porosity due to inadequate heat on the mechanical properties, are presented in this chapter. In addition, the need for support structures when manufacturing the 3D parts to maintain structural stability is also included in this study. The demand for post-manufacturing processes to perform surface machining, grinding to smooth the outside surfaces, and annealing to minimize the residual stresses may be requested by the customers that can be costly and time-consuming. Moreover, nondestructive inspection and some limited amount of testing is in some cases necessary for analysts to check the integrity of 3D printing parts. Finally, for damage tolerance analysis of 3D-manufactured parts, material allowables are needed to find out if the part can survive the service load environment. These allowables must be obtained based on acceptable standard testing techniques; otherwise, results of analysis can have large errors. Furthermore, this work presents a comprehensive survey of the diverse applications of 3D-printed composites across industries such as aerospace, automotive, medical devices, and construction. Case studies highlight successful implementations, showcasing how this technology has developed product design, prototyping, and manufacturing processes. Lastly, this chapter provides information on potential advancements in 3D manufacturing composite parts that can shape the future landscape of composite materials.
