TY - GEN
T1 - Autonomous Continuous Fiber Infill Generation for Composites 3D Printing
AU - Hernandez, Mariana R.
AU - Teker, Aytac
AU - Pochiraju, Kishore V.
N1 - Publisher Copyright:
© 2023 by DEStech Publications, Inc. and American Society for Composites. All rights reserved.
PY - 2023
Y1 - 2023
N2 - Additive Manufacturing (AM) techniques are advantageous in manufacturing polymeric composites over traditional procedures that require molding, mounting, etching, and post-cleaning. AM is conducive to material allocation reinforcing in critical regions or directions by increasing the fiber volume fraction or by the selective orientation of the fibers. However, state-of-the-art entails fiber orientations be specified manually during the slicing and infill planning steps without any awareness of the desired material properties. In this paper, we formulate and solve the continuous fiber infilling with additively manufactured parts as a fiber path planning problem with constraints on the desired minimum fiber-volume fraction and optimal fiber orientations. The autonomous path planner maximizes the fiber-volume fraction in areas requiring high stiffness while minimizing the continuous-carbon filament in the rest of the part. The fiber orientation is also optimized to maximize the use of continuous carbon filaments. The software tools for generating continuous carbon fiber infills packaged with commercial composite 3D printers cannot automatically satisfy machine-imposed constraints, and the user is often asked to provide the infill geometries manually. The algorithms presented in this paper consider the geometry, stiffness requirements, and printing device constraints while formulating the infill structure. The algorithm was implemented into an open-source parametric 3D modeler. The implementation imports the mesh file representing the solid geometry, cleans and repairs the mesh, calculates the space between faces, and slices the part. Before creating the infill path, the algorithm obtains the face and hole contours and establishes the continuous carbon infill regions. The continuous carbon fiber placement paths are then determined within the infill region to maximize the fiber volume fraction while satisfying the machine constraints. The paper describes solutions with continuous fiber infilling using several example part geometries.
AB - Additive Manufacturing (AM) techniques are advantageous in manufacturing polymeric composites over traditional procedures that require molding, mounting, etching, and post-cleaning. AM is conducive to material allocation reinforcing in critical regions or directions by increasing the fiber volume fraction or by the selective orientation of the fibers. However, state-of-the-art entails fiber orientations be specified manually during the slicing and infill planning steps without any awareness of the desired material properties. In this paper, we formulate and solve the continuous fiber infilling with additively manufactured parts as a fiber path planning problem with constraints on the desired minimum fiber-volume fraction and optimal fiber orientations. The autonomous path planner maximizes the fiber-volume fraction in areas requiring high stiffness while minimizing the continuous-carbon filament in the rest of the part. The fiber orientation is also optimized to maximize the use of continuous carbon filaments. The software tools for generating continuous carbon fiber infills packaged with commercial composite 3D printers cannot automatically satisfy machine-imposed constraints, and the user is often asked to provide the infill geometries manually. The algorithms presented in this paper consider the geometry, stiffness requirements, and printing device constraints while formulating the infill structure. The algorithm was implemented into an open-source parametric 3D modeler. The implementation imports the mesh file representing the solid geometry, cleans and repairs the mesh, calculates the space between faces, and slices the part. Before creating the infill path, the algorithm obtains the face and hole contours and establishes the continuous carbon infill regions. The continuous carbon fiber placement paths are then determined within the infill region to maximize the fiber volume fraction while satisfying the machine constraints. The paper describes solutions with continuous fiber infilling using several example part geometries.
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M3 - Conference contribution
AN - SCOPUS:85178617604
T3 - Proceedings of the American Society for Composites - 38th Technical Conference, ASC 2023
SP - 1784
EP - 1797
BT - Proceedings of the American Society for Composites - 38th Technical Conference, ASC 2023
A2 - Maiaru, Marianna
A2 - Odegard, Gregory
A2 - Bednarcyk, Brett
A2 - Pineda, Evan
T2 - 38th Technical Conference of the American Society for Composites, ASC 2023
Y2 - 18 September 2023 through 20 September 2023
ER -