1. Investigation on the mechanical and environmental behaviour of 3D-printed molds for manufacturing of CFRP components.
- Author
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Andreozzi, Marina, Bianchi, Iacopo, Mancia, Tommaso, and Simoncini, Michela
- Subjects
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CARBON fiber-reinforced plastics , *HEAT treatment , *STRAINS & stresses (Mechanics) , *COORDINATE measuring machines , *PRODUCT life cycle assessment - Abstract
This paper provides a comprehensive evaluation of using 3D-printed composite molds to produce components for the automotive sector in carbon fiber-reinforced polymers (CFRPs). Two molds in Carbon PA, i.e. PA6 reinforced with 20% by weight short carbon fibers, were realized via fused filament fabrication and subjected to multiple thermal cycles to simulate successive curing operations. Mold distortions were measured using a coordinate measuring machine before and after each heat treatment. Additionally, finite element method (FEM) and life cycle assessment (LCA) analyses were performed to obtain a complete overview of the 3D printed mold use and provide an industrial decision-making tool. Results showed that the mold distortion increases with temperature, and the clamping effect is more pronounced at the mold's edges, and it is reduced in the center. Irrespective of the thermal cycle temperature, the highest distortion was observed on the upper surface, with reduced deformation on the composite layup plane. FEM simulations confirmed that, following bolt tightening, the molds can resist without critical stress or plastic deformation. LCA analysis demonstrated that 3D-printed molds reduce environmental impact by 18% compared to aluminum ones, leading to more sustainability benefits for low-volume production, making them ideal for prototyping, small batches, or customized components. The potential of 3D-printed molds as a valid alternative to traditional methods to produce low-volume CFRPs was demonstrated. The implications of this study highlight the efficiency and sustainability benefits of 3D printing technology in composite manufacturing, offering a flexible solution for industries where small production runs and customization are critical. [ABSTRACT FROM AUTHOR]
- Published
- 2024
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