Investigation on process window of 3D printed continuous glass fiber‐reinforced thermosetting composites

Abstract

Abstract3D‐printed continuous fiber composites offer high strength in desired directions, which has attracted researchers' attention. In general, thermoset composites provide better results than their thermoplastics counterparts due to their higher modulus, low viscosity resin, better fiber impregnation, and proper adhesion to the reinforcing fibers. This study, examined the fabrication of continuous fiber‐reinforced thermoset composites (CFTCs) using 3D printing technology. This investigation focused on the optimization of process parameters for UV‐curable composites. Using systematic experimentation, the proper nozzle diameter (2.0 mm), print thickness (0.6 mm), and print speed (200 mm/min) were determined, resulting in the attainment of optimal fiber weight ratio and impregnation. The optimized CFTC exhibited an exceptional ultimate tensile strength of 276.26 MPa, exceeding existing literature data on printed short fiber composites. Additionally, under flexural loading conditions, an ultimate strength of 76.7 MPa was observed, which is characterized by a more ductile failure than a brittle fracture mode. The results of this research demonstrate the significant potential of 3D‐printed CFTCs and establish a robust process window for achieving exceptional mechanical properties. These findings hold promise for a wide range of applications demanding high‐strength composite materials.Highlights Continuous fiber reinforced thermoset composites successfully printed. Determination of a process window for printed CFTCs. The optimized CFTC exhibited a remarkable ultimate tensile strength of 276.26 MPa. Ultimate strength of 76.7 MPa was achieved under flexural loading.