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The technology of continuous fibre-reinforced polymers: a review on extrusion additive manufacturing methods

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Abstract

Additive manufacturing technologies have transitioned from the fabrication of prototypes to final product manufacturing with competitive mechanical performance. The use of materials with high strength to weight ratio, and more specifically continuous fibre-reinforced composites, has demonstrated potential when fabricated through fused filament fabrication (FFF). The development and evaluation of such technologies has attracted a lot of attention in recent years, from both academic researchers and from industry, and a plethora of different techniques for its achievement has been proposed. This review presents different methods of FFF for the fabrication of continuous fibre-reinforced composite components as described in both patent and scholarly research literature. Different print head designs and techniques for combining and depositing polymers reinforced with continuous fibre have been developed including pre-impregnation, the use of multiple nozzles for the separate deposition of the fibre and the matrix material, and in situ impregnation of the reinforcing fibre with the matrix material. This review identifies the challenges associated with each of these approaches such as achieving a successful fibre/matrix impregnation, cutting of the continuous fibres during processing, and the introduction of high-performance thermoplastic polymers as the matrix material.

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Acknowledgements

The authors would like to acknowledge the facilities of the Advanced Manufacturing Precinct and the Centre for Additive Manufacturing at RMIT University, Melbourne, Australia.

Funding

The authors would like to recognise the financial support of Siemens Gas & Power, Germany.

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Authors and Affiliations

  1. Centre for Additive Manufacturing, School of Engineering, RMIT University, Melbourne, VIC, Australia

    Chrysoula Pandelidi, Stuart Bateman & Milan Brandt

  2. Siemens AG, Gas and Power, Power Generation Operations, Berlin, Germany

    Sebastian Piegert, Rene Hoehner & Ingomar Kelbassa

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  1. Chrysoula Pandelidi
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  2. Stuart Bateman
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  4. Rene Hoehner
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Contributions

Chrysoula Pandelidi: Conceptualisation and writing - original draft

Stuart Bateman: Conceptualisation, supervision, and writing - editing

Sebastian Piegert: Fund acquisition and writing - editing

Rene Hoehner: Writing - editing

Ingomar Kelbassa: Fund acquisition

Milan Brandt: Fund acquisition, conceptualisation, supervision, and writing - editing

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Correspondence to Chrysoula Pandelidi.

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Pandelidi, C., Bateman, S., Piegert, S. et al. The technology of continuous fibre-reinforced polymers: a review on extrusion additive manufacturing methods. Int J Adv Manuf Technol 113, 3057–3077 (2021). https://doi.org/10.1007/s00170-021-06837-6

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