Method to measure orientation of discontinuous fiber embedded in the polymer matrix from computerized tomography scan data

Usage of discontinuous glass fibers in injection- and compression-molded resin components is rapidly increasing to improve their mechanical properties. Since added fiber contributes to more strength along the fiber direction compared with transverse direction, the mechanical properties of such components strongly depend on the fiber orientation. Therefore, it is important to estimate the fiber orientation distribution in such materials. In this article, we are presenting a recently developed method to estimate fiber orientation using micro computerized tomography (CT) scan-generated three-dimensional (3-D) image of fibers. However, the large size of the CT scan-generated 3-D image often makes it difficult to separate each fiber and extract end point information. In this article, a novel method to address this challenge is presented. The micro-CT images were broken into finite volume, reducing data size, and then each fiber was reduced to its own centerline, using Mimics((R)) Innovation Suite (Materialise NV), further reducing the data size. These 3-D centerlines were then used to quantify the second-order orientation tensor. The results from the proposed method are compared with the measurements using well-established industry standard approach called the method of ellipses for validation. The key challenges in estimating the fiber orientation are identified and future improvements are proposed.