Fabrication and tensile testing of 3D printed continuous wire polymer composites

Purpose This paper aims to evaluate and predict the tensile properties of additively manufactured continuous wire polymer composites (CWPCs). Design/methodology/approach An open-source 3D printer was modified to print CWPCs where metal wires act as a reinforcement within a polymer matrix. The influence of different wire materials and diameters on the tensile modulus and ultimate tensile strength was studied. Different polymer matrixes were used to investigate the effect of the matrix on CWPCs' tensile properties. The behaviour of samples was predicted analytically using the rule of mixture micromechanical approach and investigated experimentally using an American society for testing and materials standard tensile test. Findings Experimental results showed improvement in the elastic modulus and ultimate strength of CWPCs compared with non-reinforced specimens. Deviation between the experimental data and the analytical prediction was found to be dependent on the matrix type, wire volume fraction and wire material. Originality/value This paper introduces novel continuous metal wire-reinforced 3D printed composites. The continuous wire inside the print can be used as a strain gauge which can give an early alert for material failure. Applications for CWPCs include 3D-printed pressure and temperature sensors which measure the change in the wire's electrical resistance and 3D-printed heaters which would work by supplying current through continuous wires.