Performance Study of 3D Printed Continuous Fiber-Reinforced Polymer Composites Using Taguchi Method

Fused filament fabrication-based 3D printing technology is considered a new approach for manufacturing fiber-reinforced polymer parts due to proper control over fiber position and orientation within the polymer matrix. In this study, the performance of 3D printed composites of Onyx reinforced with continuous glass, Kevlar, and carbon fibers has been examined. The Markforged Mark Two 3D printer was used to develop tensile test specimens as per ASTM D638 standard. An L9 array of the Taguchi design of experiment is employed for experimentation. The effect of fiber type, fiber volume, fiber isotropic angle, and fiber concentric rings on tensile properties has been studied. After analysis of the results, it is observed that tensile properties are significantly improved on reinforcement with continuous fiber. The maximum tensile strength of 369 MPa and maximum tensile modulus of 3.4 GPa were achieved with 45% carbon fiber reinforced at 0 degrees isotropic angle and three numbers of concentric rings in each layer. Measurement was also carried out to assess the dimensional quality of the test specimens and found as precise. Scanning electron microscopy indicates the presence of voids at multiple locations around the microfibers, causing a reduction in the tensile properties. The individual micro-fibers were seen as misaligned, mainly in the case of Kevlar fiber. The present work may guide the professionals working with continuous fiber-reinforced 3D printed polymer composites in selecting appropriate process conditions for their specific needs.