Performance-driven 3D printing of continuous curved fibre reinforced polymer composites a preliminary numerical study

Abstract: This paper presents a new concept to place continuous curved fibres for CFRP composites, which can be fulfilled by potential additive or hybrid manufacturing technology. Based on the loading condition, principal stress trajectories are generated through finite element analysis (FEA) and used as the guidance of the placement paths for carbon fibres. Three numerical cases, an open-hole single ply lamina under uniaxial tension and an open-hole cross-ply laminate under biaxial tension and normal pressure, are studied and compared with traditional reinforced composites with unidirectional fibres. The modelling results show that the stress concentration in both fibre and matrix are reduced significantly by the curved fibre placement and the stiffness of CFRP composites have been improved. This concept of performance-driven optimization method could lead to a useful tool for the design of future 3D printing process for fibre reinforced composites.