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Ongoing research in additive manufacturing towards structural and industrial application has led to the use of commingled roving as a manufacturing feedstock for printing high fiber volume fraction composites. The prospects of using this technology for high performance applications necessitates the need for a comprehensive experimental investigation into the effects of processing parameters on the quality of an additively manufactured composite printed from commingled roving feedstock. In this work, transverse flexure and void fraction matrix pyrolysis testing are both performed to evaluate composite quality. The transverse flexure test is a testing approach that evaluates the quality of the interfacial fiber-matrix bond while the void fraction test estimates the void content in the printed composite. A full observational study consisting of 27 different test combinations is done to investigate the effects of three different process parameters namely, temperature, pressure, and print speed across three different levels. Composite samples were made from commingled roving of E-glass and amorphous PET using an in-house built continuous fiber composite digital manufacturing system. Least squares regression analysis is performed to study the main, interaction and quadratic effects of process parameters. A statistical regression model having an R2 adjusted value of 80.1% is generated from the transverse flexure study, which is used to explain main and interaction effects and also predict performance. Response surface plots are also generated and are used to optimize process parameters which can subsequently be of help in scaling up composite manufacturing. Results show that all three process parameters are highly statistically significant at the 0.01 level of significance. Pressure * Temperature and Pressure * Printspeed are significant interaction terms. Pressure plays a weightier role when print speed is increased or temperature is decreased as it closes more voids that would ordinarily have been introduced because of drop in polymer melt viscosity. Micrographic analysis is also performed. [ABSTRACT FROM AUTHOR]

Highlights An improved approach consisting of a combination of fiber placement and fused filament fabrication is introduced for the additive manufacture (AM) of structural grade sandwich beams. Here, sandwich beams are additively manufactured using in‐situ deposition and consolidation of continuous fiber unidirectional facings made from a commingled yarn system of e‐glass fiber (~50% vol.) and amorphous PET, and a hexagonal honeycomb core structure made from PETG. Both facings and the sandwich core are manufactured on a single machine, in one sequence (skin‐core‐skin), employing the benefit of matrix compatibility to create autohesion at the interfaces. Flexural and transverse shear rigidity are determined experimentally and compared with analytical predictions and show correlation to within 3%. Flexural strength and core shear strength are also measured. Post‐mortem examinations show that core fracture and core facing debond were the dominant failure mode in flexure. Single cantilever beam tests were performed to evaluate core facing debond toughness. Subsequently, surface preheat using infrared heaters was utilized to increase autohesion between core and facing. The results show debond toughness was increased 4 times using infrared heating. This research effort presents a manufacturing approach that has the potential for the AM of stiff, well bonded, structural grade sandwich beams, in an integrated sequence, employing in‐situ consolidation to the facings, without the need for the use of intermediate adhesives for skin‐to‐core bonding. An improved additive manufacturing technique for making sandwich panels is developed. Sandwich panel facings have fiber volume fractions of approximately 50%. Surface preheat improves core‐to‐facing debond toughness by a factor of 4. Top and bottom facings are consolidated during manufacture leading to better properties. Experimental results are compared to analytical predictions and show good correlation. [ABSTRACT FROM AUTHOR]

As an alternative to traditional composite sandwich panels, grid stiffened laminates using continuous fiber in the stiffeners have the potential to demonstrate high out-of-plane stiffness to weight and allow new opportunities related to high performance design. However, only limited results have been presented on the production of high aspect ratio grid stiffeners, and the majority of the previous efforts have required a significant investment in tooling. Thus, while promising, the traditional methods of producing composite grid stiffened structures require complex tooling to develop the geometry, position, and orientation of the stiffening ribs. This study demonstrates the use of direct digital manufacture to produce continuous fiber reinforced high aspect ratio composite grid stiffeners, from glass fiber/thermoplastic commingled tow feedstock, with radically reduced tooling requirements. Stiffener specimens with a height to width aspect ratio of 6:1 were produced by consolidating 80 layers of commingled tow onto a flat tooling plate using an automated continuous fiber extrusion system. The method of placement and consolidation is described, and process parameters are shown to enable the production of high-quality specimens without complex tooling. The quality through the height of printed stiffeners was evaluated by the experimental measurement of fiber volume fraction and void content and by optical microscopy. The results of this study suggest that the application of direct digital manufacture to the placement and consolidation of commingled tow for the fabrication of high aspect ratio grid stiffeners, without the need for tooling, can readily achieve fiber volume fractions greater than 50% and void fractions as low as 5%. [ABSTRACT FROM AUTHOR]