Multi-scale analysis for 3D printed continuous fiber reinforced thermoplastic composites

Abstract With the development of additive manufacturing technology, the designing and fabrication of continuous fiber reinforced thermoplastic composites (CFRTPCs) are concerned and studied more extensively. In this paper, both melting-deposition-cooling manufacturing process and the mechanical properties of 3D printed CFRTPCs are simulated. First, theoretical and numerical models of the 3D printing process for CFRTPCs are proposed, which take the resin infiltration, temperature changes and resin curing into account. Second, influences of the stacking method, the aspect ratio of the oval bead, the width and height between beads on resin infiltration and density of 3D printed CFRTPCs are analyzed. Finally, the mechanical properties of 3D printed CFRTPCs are predicted using multi-scale simulation methods. This work provides the simulation method and theoretical basis for the design and evaluation of 3D printed CFRTPCs.