Layer Height Treatments on Uniaxial Compression Performance of Industrial Large-Scale Additively Manufactured Polymer Composite Structures

The chapter delves into the impact of layer height treatments on the uniaxial compression performance of industrial large-scale additively manufactured polymer composite structures. It begins with an introduction to the current state of research in industrial large-scale polymer additive manufacturing (ILSPAM) and identifies gaps in the literature regarding the effects of processing parameters on structural performance. The authors then outline their research goals, which include demonstrating the manufacturability of large structures using ILSPAM, identifying and categorizing manufacturing defects, and evaluating the structural response to loading. The methodology involves producing prototype pile footings using a CI BAAM ILSPAM machine and subjecting them to cyclic uniaxial compression tests. The experimental results reveal that the prototypes successfully met the nominal critical dimensions and exhibited various defects such as uneven surface finish and warping. The compression tests showed that the structures could withstand repeated loads at a safety factor of 5, with limited displacement. The data also indicated a negative correlation between layer height and stiffness, suggesting that taller layer heights promise increased manufacturing rates. The chapter concludes with a discussion of the findings and proposes future work, including additional mechanical testing and further investigation into the impact of material selection and temperature control on structural performance.