4. DESCRIPTION
Field of invention
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ADDITIVE MANUFACTURING, FUSED DEPOSITION MODELING.
Background of the invention
The development and application of composite materials have revolutionized various industries, ranging from
aerospace and automotive to healthcare and consumer goods. These materials, which typically consist of two or more
constituent materials with significantly different physical or chemical properties, are engineered to achieve superior
performance characteristics compared to traditional materials. Additive manufacturing, also known as 3D printing,
has further expanded the possibilities for composite material design and production, offering unprecedented freedom
in creating complex geometries and structures.
One such composite material pairing under investigation is Onyx carbon fiber and ULTEM 9085, both produced
using additive manufacturing technology. Onyx carbon fiber is a composite material that combines nylon with
chopped carbon fibers, resulting in a lightweight yet robust material with excellent stiffness and strength-to-weight
ratio; ULTEM 9085, on the other hand, is a high-performance thermoplastic known for its exceptional strength, heat
resistance, and chemical resistance, making it suitable for demanding applications in aerospace, automotive, and other industries.
The comparison of the tensile mechanical properties of these two composite materials is crucial for understanding
their suitability for various engineering applications. Tensile mechanical properties refer to the behavior of a material
under tensile (stretching or pulling) forces, including parameters such as tensile strength, Young‘s modulus, and
elongation at break. By analyzing these properties, engineers can assess the structural integrity, durability, and
performance of the materials in real-world conditions.
The additive manufacturing process introduces unique challenges and opportunities for composite material
production. Layer-by-layer deposition allows for precise control over material distribution and orientation, enabling
the customization of material properties based on design requirements. However, factors such as interlayer adhesion,
porosity, and residual stresses can influence the mechanical properties of the final product.
Understanding how Onyx carbon fiber and ULTEM 9085 perform under tensile loading will inform material selection decisions in industries where lightweight, high-strength materials are in demand. By elucidating the strengths and
limitations of each material, engineers can optimize designs, enhance product performance, and accelerate innovation in additive manufacturing applications.
Brief Description of the Drawing
The properties of the material, for example, for advance applications such as end use pans are an imponant aspect
in the assessment of additive manufacturihg. As a semi~molten thermoplastic material solidifies, a contraction of the
volume occurs, causing poor inner layer bonding. Therefore, a process parameter level must be determined that
provides the maximum flexural properties. The flexural properties made on the FDM obviously depend on the
processing parameters. In this study, the four FDM process parameters were included for examination and shown in
Table 5.], they are 1. Raster Angle, 2. Raster Width, 3. Air gap, 4. Contour Width which are shown in the Fig5.1
They are relevant according to the preliminary pilot studies and the low and high level values recommended by the
equipment manufacturer. A|1 parameters are describable and as follows: '
l. Raster angle: This is the angle measured from the X-axis of the plane relative to a raster. The specification of
the raster angle can be very important in pans with small curves or sharp comers
2. Raster width: This is the width of the material bead used for rastérs. Larger values of Raster width will build
a part with a stronger interior. Smaller values of rasters consume less time and material.
3. Contour Widtli: This is the width of the material bead used for contours. Smaller values of preferred contour
width will build a pan with a better surface finish. Larger values will require less time and material.
4. Air gap: Air gaps are adjustable between two adjacent tool paths. The pair of adjacent tool paths may be any
combination of contours and rasters. ‘
Adjacent tasters air gap: The air gap spacing between parallel raster lines used to fill the region
Contours and rasters air gap: The air gap spacing between the inner most contour and the outside edge of the
raster fill.
Contour and contour air gap: When Using Multiple contours this value defines the air gap spacing between
successive contours.
Detailed Description of the Invention
The invention under scrutiny entails a comprehensive comparison of the tensile mechanical properties of two distinct
composite materials: Onyx carbon fiber and ULTEM 9085, both manufactured-through additive manufacturing
technology. This innovative endeavor aims to elucidate the performance disparities and potential applications of these
materials in various industrial sectors.
Onyx carbon fiber represents a cutting-edge composite material renowned for its exceptional strength-to-weight ratio
and durability. Crafted from a blend of chopped carbon fiber and nylon, Onyx exhibits superior mechanical
properties, making it a preferred choice for engineering applications requiring high-strength components. The »
additive manufacturing process employed in its production ensures precise fabrication and optimal material
distribution, further enhancing its mechanical integrity.
Contrarily, ULTEM 9085 stands as a formidable competitor, boasting imique thermoplastic properties and high temperature
resistance. Renowned for its excellent chemical resistance and flame retardant, ULTEM 9085 finds
widespread utilization in aerospace, automotive, and medical industries. Its compatibility with additive manufacturing techniques facilitates the fabrication of intricate components with uncompromising mechanical performance.
The detailed comparison of these materials encompasses various parameters, including tensile strength, modulus of elasticity, and elongation at break. Through meticulous experimentation and analysis, the mechanical behavior of both materials under tensile loading conditions is systematically evaluated and compared. This comparative study
seeks to delineate the inherent strengths and limitations of each material, providing valuable insights for engineers
and designers seeking to optimize material selection for specific applications.
Furthermore, the research delves into the influence of additive manufacturing parameters, such as printing
orientation, infill density, and layer thickness, on the mechanical properties of Onyx carbon fiber and ULTEM 9085.
By elucidating the interplay between manufacturing parameters and material performance, this study aims to optimize
the fabrication process to achieve superior mechanical properties and dimensional accuracy.
In essence, this invention embodies a meticulous exploration of the tensile mechanical properties of Onyx carbon
fiber and ULTEM 9085, elucidating their performance characteristics and potential applications in additive
manufacturing. By providing comprehensive insights into material behavior and manufacturing optimization strategies, this research contributes to the advancement of composite material science and engineering.
8. WE CLAIM
1. A method for optimizing the tensile mechanical properties of composite materials produced through additive
manufacturing, compn'sing the steps of systematically varying process parameters including raster angle, raster
width, contour width, and air gap to achieve maximum flexural properties and interlayer bonding.
2. A system for evaluating the tensile strength, modulus of elasticity, and elongation at break of composite materials, such as Onyx carbon fiber and ULTEM 9085, fabricated using additive manufacturing techniques, wherein said system includes a testing apparatus capable of subjecting specimens to controlled tensile loading
conditions.