materials

Article
Performance of 3D-Printed
Continuous-Carbon-Fiber-Reinforced Plastics
with Pressure
Jun Zhang 1 , Zude Zhou 1 , Fan Zhang 1, * , Yuegang Tan 1 , Yiwen Tu 1 and Baojun Yang 2
1 School of Mechanical and Electronic Engineering, Wuhan University of Technology, WuHan 430070, China;
junzhang_918@126.com (J.Z.); zudezhou@whut.edu.cn (Z.Z.); ygtan@whut.edu.cn (Y.T.);
ywtu_whut@163.com (Y.T.)
2 Chongqing Huashu Robotics Co., Ltd., FoShan 528234, China; baojunyang_huashu@126.com
* Correspondence: fanzhang_1128@163.com




Received: 9 December 2019; Accepted: 10 January 2020; Published: 19 January 2020


Abstract: Fused Deposition Modeling (FDM) has been investigated as a low-cost manufacturing
method for fiber-reinforced composites. The traditional and mature technology for manufacturing
continuous-carbon-fiber-reinforced plastics is Automated Fiber Placement (AFP), which uses
a consolidation roller and an autoclave process to improve the quality of parts. Compared to
AFP, FDM is simple in design and operation but lacks the ability to pressurize and heat the model.
In this work, a novel method for printing continuous carbon-fiber-reinforced plastics with a pressure
roller was investigated. First, the path processing of the pressure roller was researched, which will
reduce the number of rotations of the pressure roller and increase the service life of the equipment and
the efficiency of printing. Thereafter, three specimens were printed under different pressures and the
tensile and bending strength of specimens were tested. The tensile strength and bending strength of
specimens were enhanced to 644.8 MPa and 401.24 MPa by increasing the pressure, compared to the
tensile strength and bending strength of specimens without pressure of 109.9 MPa and 163.13 MPa.
However, excessive pressure will destroy the path of the continuous carbon fiber (CCF) and the
surface quality of the model, and may even lead to printing failure.

Keywords: continuous carbon fiber; pressure; composites; 3D printing; FDM

1. Introduction
Carbon fiber reinforced plastics (CFRPs) have been widely used in the fields of automobile
manufacturing and aerospace due to their excellent mechanical properties such as light weight,
high strength, etc. [1,2]. Automated Tape Laying (ATL) and Automated Fiber Placement (AFP) are two
commonly used technologies for CFRP manufacturing at present [3,4]. However, the technologies
cannot be popularized in civilian applications such as the sports industry (carbon fiber bicycles, carbon
fiber badminton rackets etc.) because of the expensive equipment and the complex manufacturing
process. The challenge of manufacturing CFRPs is combining the reinforcement fibers into the plastics
with the orientation control of fibers and low cost [5].
Fused Deposition Modeling (FDM) has developed rapidly due to its low production cost and
the high degree of automation in recent years [6,7]. This technology can manufacture complex parts
with various thermoplastic filaments such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene
(ABS), and Nylon, etc. However, one limitation of FDM is the poor mechanical properties of parts [8,9].
The strength of parts printed by FDM is so low that the parts can’t be used directly, the parts are
used as a mould to validate the rationality of the design model usually. Wang et al. added thermally
expandable microspheres to diminish voids between deposition lines on the basis of FDM [10]. It proves

Materials 2020, 13, 471; doi:10.3390/ma13020471 www.mdpi.com/journal/materials

Materials 2020, 13, 471 2 of 15

that adding the thermally expandable microsphere to the thermoplastic filaments can improve the
mechanical properties of parts fabricated by FDM. Sithiprumnea et al. studied the influence of
exfoliated graphene nanoplatelets (xGnPs) on the ABS. The elastic modulus and dynamic storage
modulus of 3D-printed parts along three different build orientations were increased by the presence of
xGnPs in the ABS matrix [11]. Kalappa et al. fabricated the conductive polymer nanocomposites based
on FDM and analyzed their mechanical, electrical and electromagnetic-induction-shielding properties
of the nanocomposite [12]. Much work has been done to study the properties of composites based on
FDM, the obvious strength improvement of reinforced material is combining the thermoplastics with
Carbon Fiber (CF). Table 1 presents an overview of different studies on printing CFRPs, showing the
reinforcement of CF on thermoplastics.

Table 1. The overview of studies on printing of reinforced filaments.xGnPs: graphene nanoplatelets,

SCF: short carbon fiber, CCF: continuous carbon fiber, CKF: continuous Kevlar fibre, CGF: continuous
glass fibre, ABS: acrylonitrile butadiene styrene, PLA: polylactic acid, PU: poly urethane, PVA: polyvinyl
alcohol, PA6: polyamide 6, PTFE: polytetrafluoroethylene, PP: polypropylene.

Overview of Studies on Printing of Reinforced Filaments

Study Reinforcement Matrix Tensile Strength Reinforcement
Sithiprumnea Dul. [11] xGnPs ABS Strength from 33.4 MPa to 38.2 MPa
Tekinalp HL et al. [13] SCF ABS Strength from 35 MPa to 65 MPa
Xiu H et al. [14] SCF PLA and PU Strength from 68.3 MPa to 100 MPa
Istvánné Ráthy et al. [15] SCF PVA Strength from 39 MPa to 51 MPa
Karsli NG et al. [16] SCF PA6 Strength from 38 MPa to 86 MPa
Li ZH et al. [17] SCF PTFE Strength from 33.8 MPa to 85 MPa
Ashori A et al. [18] SCF PP Strength from 38.2 MPa to 43.4 MPa
Quan Z et al. [19] SCF ABS Strength from 3.14 MPa to 4.9 MPa
Bettini P et al. [20] CCF PLA Strength from 34 MPa to 203 MPa
Matsuzaki R et al. [21] CCF PLA Strength from 40 MPa to 185 MPa
Li N et al. [22] CCF PLA Strength from 28 MPa to 91 MPa
Tian X et al. [23] CCF PLA Strength from 110 MPa to 335 MPa
Yang C et al. [24] CCF ABS Strength from 30 MPa to 200 MPa
Hu Q et al. [25] CCF PLA Strength from 74.2 MPa to 541.7 MPa
Melenka GW et al. [26] Continuous Kevlar Fiber Nylon Strength from 5 Pa to 92 Pa
Dickson AN et al. [27] CGF, CCF, CKF Nylon Strength from 61 Pa to 444 Pa

The reinforcement of CF on thermoplastics can be summarized into two ways: combining with
short carbon fiber (SCF) and combining with continuous carbon fiber (CCF). The effect of SCF on
thermoplastics is based on the orientation, dispersion, and void formation of fibers. The bridging and
pulling-out of fibers in thermoplastics can increase the strength of PLA, ABS, and PVA composites.
The interfacial interaction and glass-transition temperature of short-carbon-fiber-reinforced plastics
(SCFRPs) are related to the CF content [13–15]. Karsli et al. investigated the effects of fiber length
content on the mechanical, thermal, and morphological properties of CF reinforced PA6 composites [16].
The results revealed that the tensile strength of PA6 composites increased from 44 MPa to 86 MPa as the
CF content increased to 20%. Li et al. investigated the effects of SCF length on polytetrafluoroethylene
(PTFE), and found that the geopolymer matrix strength increased from 33.8 to 85 MPa as the length of
SCF increased to 80 um [17]. Ashori et al. studied the improvement in mechanical of polypropylene
(PP) reinforced by SCF and xGnPs [18]. The xGnPs can further increase the strength of SCF–PP
composites. However, it was found that the properties of parts printed by SCFRPs were slightly better
than pure thermoplastic, while additional porosity and poor bonding can be detected because of the
Materials 2020, 13, 471 3 of 15

presence of SCF [19]. With a continuing increase in fiber length from 80 um, the deformation of SCF
decreased, and the gaps between the SCF and PTFE increased gradually [17].
The2019,
Materials ideal solution
12, x FOR to achieve better properties of parts by FDM is printing 3with
PEER REVIEW of 15
continuous-carbon-fiber-reinforced plastics (CCFRPs) [20]. The orientation of CCFs in composites
interfacial
is interaction
easily controlled of the
and CCFs CCFs
have with specific
a smaller the thermoplastics.
surface area than According
SCFs, which to current
increasesresearch, two
the interfacial
approaches—real-time
interaction of the CCFs with 3D theprinting of CCFs with
thermoplastics. the thermoplastic
According and printing
to current research, CCFRPs based on
two approaches—real-time
prepared
3D CCFRPs—are
printing of CCFs with applied to manufacturing
the thermoplastic CCFRPs
and printing using FDM.
CCFRPs based As on shown
prepared in Figure 1a, the
CCFRPs—are
CCFs were
applied impregnated with
to manufacturing thermoplastic
CCFRPs using FDM. in the
As nozzle
shown and the CCFRPs
in Figure 1a, the can
CCFs be were
printed in a single
impregnated
step [21].
with The CCFsinand
thermoplastic thethermoplastic
nozzle and the are compounded
CCFRPs can be inside
printedthe
in nozzle,
a singlethestepCCFs
[21].are
Thebrought
CCFs and out
while the thermoplastic
thermoplastic are compounded is extruded
insidedepending
the nozzle,onthethe viscosity
CCFs of theout
are brought thermoplastic. Based on this
while the thermoplastic is
method, Nanya
extruded depending et al.
ontested the performance
the viscosity of CCFRPs.
of the thermoplastic. Theon
Based results indicated
this method, that et
Nanya CCF has a
al. tested
significant
the effect of
performance onCCFRPs.
the printing model indicated
The results performance thatand
CCFthehaspreferable
a significantbonding interfaces
effect on were
the printing
achieved
model of CCFRPsand
performance [22].the
Tian et al. studied
preferable the interfaces
bonding influencing of process
were achieved parameters
of CCFRPs on[22].
the interfaces
Tian et al.
and performance
studied the influencing of of
printed
processcomposites.
parameters on Thethestrength
interfacesofandprinted composites
performance increases
of printed with
composites.
increasing
The strengththeof content
printed of CCF [23,24].
composites However,
increases with CCFs and thermoplastic
increasing the content of CCF resin [23,24].
are mixed at the
However,
melting
CCFs andzone of the extrusion
thermoplastic resin arehead, which
mixed willmelting
at the cause thezonenon-uniform
of the extrusiondistribution
head, which of CCFs
will in the
cause
resin
the and the insufficiency
non-uniform distributionof of compounding
CCFs in the resin dueand to the
theinsufficiency
not enough of melting zone. Asdue
compounding a result, the
to the not
reinforcement
enough meltingofzone.
CCFsAs to aresin is weakened
result, to some of
the reinforcement extent.
CCFs to resin is weakened to some extent.

Figure 1. (a) The real-time 3D printing of CCF with thermoplastic and (b) printing CCFRPs based on
Figure 1. (a) The real-time 3D printing of CCF with thermoplastic and (b) printing CCFRPs based on
prepared CCFRPs.
prepared CCFRPs.
The other strategy is to manufacture the CCFRPs and then print parts with the CCFRPs on
The other strategy is to manufacture the CCFRPs and then print parts with the CCFRPs on a
a FDM printer, which is a multi-step process, as shown in Figure 1b. The CCFs and thermoplastic are
FDM printer, which is a multi-step process, as shown in Figure 1b. The CCFs and thermoplastic are
compounded into CCFRPs on a specific material-preparation machine that can control the diameter
compounded into CCFRPs on a specific material-preparation machine that can control the diameter
and fiber content of CCFRPs. Then, the prepared CCFRPs are used to print the parts on the 3D
and fiber content of CCFRPs. Then, the prepared CCFRPs are used to print the parts on the 3D
printer, and the process parameters of the 3D printer need to match the continuity characteristics of
printer, and the process parameters of the 3D printer need to match the continuity characteristics of
the CCFRPs. From the perspective of composites, Liviu et al. investigated the influence of Poission’s
the CCFRPs. From the perspective of composites, Liviu et al. investigated the influence of Poission’s
ratio of different material combinations, and proposed a new formula to estimate the singularity order
ratio of different material combinations, and proposed a new formula to estimate the singularity
for the elasto-plastic stress singularity [28]. Wu et al. presented the fabrication method as well as the
order for the elasto-plastic stress singularity [28]. Wu et al. presented the fabrication method as well
microstructural and dielectric characterization of bespoke composite filaments for fused deposition
as the microstructural and dielectric characterization of bespoke composite filaments for fused
modeling (FDM) 3D printing of microwave devices [29]. The method may be used as a guide for the
deposition modeling (FDM) 3D printing of microwave devices [29]. The method may be used as a
successful fabrication of many types of composite filament with varying functions for a broad range of
guide for the successful fabrication of many types of composite filament with varying functions for
applications. Goh et al. provide a database of the mechanical properties of additively manufactured
a broad range of applications. Goh et al. provide a database of the mechanical properties of
polymeric materials fabricated using material extrusion to identify the research gaps [30]. Jahangir
additively manufactured polymeric materials fabricated using material extrusion to identify the
et al. studied the reinforcement of material extrusion 3D printed polycarbonate using continuous
research gaps [30]. Jahangir et al. studied the reinforcement of material extrusion 3D printed
carbon fiber [31]. Hu et al. analyzed the effect on the performance of the model caused by printing
polycarbonate using continuous carbon fiber [31]. Hu et al. analyzed the effect on the performance
time, printing speed, and layer thickness based on this method [25]. The results indicated that the
of the model caused by printing time, printing speed, and layer thickness based on this method [25].
flexural strength and flexural modulus of printed composites significantly improved with the proposed
The results indicated that the flexural strength and flexural modulus of printed composites
method with specified printing parameters. Melenka et al. evaluated and predicted the elasticity of
significantly improved with the proposed method with specified printing parameters. Melenka et al.
evaluated and predicted the elasticity of the fiber-reinforced 3D-printed structures by MarkOne,
which is a 3D printer made by Markforged Company for printing CCFRPs [26]. Dickson et al.
assessed the performance of continuous carbon-, Kevlar-, and glass-fiber-reinforced composites by
MarkOne [27]. However, 3D printers are simple in design and use but lack the ability to apply
additional pressure and heat to the part compared to the ATP machines [32]. Zhang et al. proposed a
Materials 2020, 13, 471 4 of 15

the fiber-reinforced 3D-printed structures by MarkOne, which is a 3D printer made by Markforged

Company for printing CCFRPs [26]. Dickson et al. assessed the performance of continuous carbon-,
Kevlar-, and glass-fiber-reinforced composites by MarkOne [27]. However, 3D printers are simple in
design and use but lack the ability to apply additional pressure and heat to the part compared to the
ATP machines [32]. Zhang et al. proposed a post-heading and pressurizing on parts printed with
Nylon and CCFRPs [33]. This process increases the interfaces in the parts printed by CCFRPs but
complicate the manufacture of CCFRP parts. Without pressure, the CCFRPs between adjacent layers
are adhered by the thermoplastic during printing, CCFRPs molecular chains of two adjacent layers do
not diffuse, and the degree of diffusion will affect the binding strength of the parts. For the manufacture
of CCFRP parts, pressure is essential. Lee et al. presented a model in the manufacturing process of
semicrystal line thermoplastic matrix composites and studied the effect of pressure on the bonding of
two adjacent layers of composites [34]. Wool et al. presented a theory of crack healing in polymers and
how the surface rearrangement stage affects the diffusion initiation function and topological features of
the interface [35]. Kim et al. presented a microscopic theory of the diffusion and randomization stages
based on the reptation model of chain dynamics by de Gennes and proved that the interlayer bonding
strength is proportional to the molecular chain diffusion [36]. Song et al. presented the interlaminar
intimate contact model and the molecular chain diffusion mode and the experimental results found the
degree of the interlaminar intimate could reach 1 when the pressure of the roller reaches 1500 N [37].
The effects of pressure on CCFRPs in the above studies are all based on using AFP to manufacture
CCFRPs, but there is less research on the preparation of CCFRPs parts on 3D printing.
To solve the above problem, we propose a novel 3D printing structure for CCFRPs that can heat
and pressurize the CCFRPs with a pressure roller during printing. Using this process, the CCFRPs are
pressurized while printing to increase the bond between layers. The path processing of the pressure
roller is designed and verified to ensure the feasibility and rationality of the algorithm. Then, the testing
of printing CCFRPs is performed and the mechanical properties of parts under pressure are analyzed.
In this paper, a pressure function is added to 3D printing for CCFRPs, and a matching pressure-roller-path
processing algorithm is studied. The results show that pressure brings an obvious improvement to the
strength of parts printed using CCFRPs. This article will contribute a new reference and data to the
application of 3D printing for CCFRPs.

2. 3D Printing of CCFRPs

2.1. The Principle of Printing CCFRPs

Figure 2 is a schematic of 3D printer for CCFRPs. The printing process of CCFRPs is completed
under the machine coordinate system of seven movements (three movements of the nozzle: X, Y, Z;
four movements of CCFRPs: F (feeding), C (cutting), R (rotating), L (lifting). The nozzle can move
by a processed path on the X, Y, and Z axis. The printing machine can finish the printing process of
the part with the movements of the nozzle and the feeding movement (F), while there is no jumping
point in the path of the part. However, jumping points inevitably exist in the path of a complex model.
This will limit the application of printing CCFRPs if the handling of jumping points is ignored [29].
Therefore, the cutting process (C) has been added to the printing. Furthermore, other types of 3D
printing for CCFRPs lack the ability to apply additional pressure and heat to the part compared to
the ATP for CCFRPs used in the current work. The pressure roller we use here is adopted to increase
adhesion between layers and the bonding of fibers in one layer. The implementation of pressure can be
decomposed into two movements: a rotating movement (R) and a lifting movement (L). The pressure
roller is rotated at a certain angle according to the path of the nozzle to ensure that the CCFRPs during
printing are pressed. The pressure roller is lifted to a suitable height before rotating to prevent the
CCFRPs from being crushed. Then the pressure roller is dropped to continue to pressurize the part
when the rotation is completed. In addition, a heating device is installed in the pressure roller to keep
the CCFRPs in a molten state for better properties of the parts.
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Figure 2. Schematic of 3D-printing machine for CCFRP.

Figure 2. Schematic of 3D-printing machine for CCFRP.
2.2. Path Processing of Pressure Roller
2.2. Path Processing of Pressure Roller
There are two kinds of paths (the path of nozzle and the path of pressure roller) in the molding
There
process of areprinting
two kinds of pathsThe
CCFRPs. (thepathpathofofthenozzle
nozzleandisthe path ofby
planned pressure
the sliced roller)
G-codein the molding
based on the
process
model. The path of the pressure roller is the same as the nozzle when the path of nozzle is aonstraight
of printing CCFRPs. The path of the nozzle is planned by the sliced G-code based the
model.
line. The
The path
path of the pressure
of the pressure roller
roller is is different
the samefrom as thethenozzle
nozzlewhen
whenthe thepath
pathofofnozzle
the nozzleis a straight
is a curve.
line. The path of the pressure roller is different from the
The 3D printing machine implements movements according to the G-code and the curves nozzle when the path of the nozzle is a of
consist
curve. The 3D printing machine implements movements according to the
many points with short distances in the G-code. The pressure roller will lift and rotate frequently if the G-code and the curves
consist
path ofis amany
curve,points
whichwith short distances
will reduce the service in life
theofG-code. Theand
the device pressure roller
efficiency of will lift and
printing. rotatethe
To solve
frequently
above problem, the curved path of pressure roller has been converted to a straight-line path. The of
if the path is a curve, which will reduce the service life of the device and efficiency flow
printing.
chart ofTo pathsolve the above
processing problem,
of the pressure theroller
curved path of
is shown in pressure roller has
Figure 3. Firstly, the been
pathsconverted
of pressuretoroller
a
straight-line
are dividedpath. into The
line andflowcurve.
chart Then
of path theprocessing of the pressure
curve is transformed roller
to a line is shown
according to thein algorithm
Figure 3. is
Firstly, the paths of pressure roller are divided into line and curve. Then
shown in Figure 4. Finally, rotating and pressing codes based on the lined path are added to complete the curve is transformed to
a line
the according
path processing to the of algorithm is shown
the pressure roller.in Figure 4. Finally, rotating and pressing codes based on
the lined path are added to complete
The flow chart for converting the curve the path ofprocessing of theto
pressure roller pressure
a line is roller.
shown in Figure 4a. The result
of this conversion is shown in Figure 4b. The solid line is theacurved
The flow chart for converting the curve of pressure roller to line is shown
path ofinthe Figure 4a. The
pressure roller,
result of this conversion is shown in Figure 4b. The solid line is the curved
the dotted line is the straight-line path of the pressure roller after conversion, and the red area is the path of the pressure
roller, the area
rolling dotted linepressure
of the is the straight-line
roller afterpath of the pressure
conversion. The curvesrollerare
after conversion,
inside and indicating
the red area, the red area that
is the
the rolling
rollingisarea of the pressure roller after conversion. The curves are
sufficient. The steps for converting curves of pressure roller into lines are as follows: inside the red area,
indicating that
First, thethe rollingpoint
starting is sufficient.
(Xn , Yn ) andThe the
steps for converting
ending point (Xm ,curves
Ym ) ofof pressure
curve roller into lines
are found.
are as follows:
Second, the maximum distance (L) of the line l((Xn , Yn ), (Xi , Yi )) with the curve
c((Xn , Ythe
First, n ), (starting i =（
Xi , Yi )),point nX+n1, Y
are and the ending point（X m , Ym）of curve are found.
n）calculated.
Third, the
Second, the size
maximumof L is compared
distance (toL(D/2 ) of− the 1); i line l（
( X nincreases.
gradually , Yn）（, X i , YDi）)is the
withdiameter
the curveof the
pressure roller.
c（
( X n Fourth,
, Yn）（, X ithe , Yi） )c((
, i = n + 1 are calculated.
Xn , Yn ), (Xi , Yi )) is converted to l((Xn , Yn ), (Xi , Yi )) while L > = (D/2 − 1),
andThird,
n = the i. size of L is compared to ( D / 2 − 1 ); i gradually increases. D is the diameter of
the pressure
Fifth, roller.
the steps above are followed to convert the curve to a line starting from (Xi , Yi ).
Fourth, the c（ ( X n , Yn） （, X i , Yi） ) is converted to l（ ( X n , Yn）, X i , Yi）
（ ) while L >=（D / 2 − 1）,
and n = i .
（X i , Yi）.
Fifth, the steps above are followed to convert the curve to a line starting from
Materials 2020, 13, 471 6 of 15
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FOR PEER
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Beginning
Beginning

Reading
Reading
Gcode
Gcode

Identifying
Identifying
path
path

YY Reading the
Reading the Calculatingthe
Calculating the Converting
Converting
Line??
Line Curve
Curve width of
width of maximum
maximum curve to
curve to
pressure roller
pressure roller spacing
spacing line
line
NN

Calculating
Calculating
angles of
angles oflines
lines

Addingthe
Adding thecodes
codesof
of
rotatingand
rotating and
pressing
pressing

Generating
Generating
newGcode
new Gcode

End
End

Figure
Figure The
3. 3.
Figure 3. flow
The
The chart
flow
flow chartfor
chart forpath
for pathprocessing
path processingof
processing of the pressure
the pressure
pressure roller.
roller.

Figure
Figure
Figure 4. (a)
4. (a)
4. (a)
The The
flow
The flow
flow chart
chart for
forfor
chart convertingcurve
converting
converting curveto
curve toline
to lineand
line and(b)
and (b)the
(b) the result
result of
result converting curve
of converting
converting curve to
curveto line.
toline.
line.
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A
A model
modelthatthatincludes
includeslines and
lines curves
and waswas
curves adopted
adopted to test
to the
test path processing
the path of pressure
processing roller.
of pressure
In Figure 5, (a) shows the model, (b) shows the path of the nozzle, (c) shows the
roller. In Figure 5, (a) shows the model, (b) shows the path of the nozzle, (c) shows the path of the path of the pressure
roller,
pressure(d) roller,
shows(d) theshows
path ofthe
thepath
nozzle andnozzle
of the the pressure
and theroller when
pressure printing
roller when the bounding
printing the box of the
bounding
model. Themodel.
box of the pressureTheroller will rotate
pressure rollersix times
will (θ1six
rotate , θ2times , θ5，θ
, θ3 , θ4(θ , θ6 )，θ
in a ，θ
build，θ ，θof)the
circle in apath and
build the
circle
curve has been converted to three lines. The area of the red line is the pressurized area
of the path and the curve has been converted to three lines. The area of the red line is the pressurized of the pressure
roller,
area ofwhich indicates
the pressure that the
roller, CCFRPs
which can that
indicates be pressurized
the CCFRPs completely.
can be pressurized completely.

Figure 5. (a) The printed model, (b) the path of the nozzle, (c) the path of the pressure roller and (d) the
path of the
Figure nozzle
5. (a) and pressure
The printed model,roller in the
(b) the pathoutermost circle(c)
of the nozzle, of the
the path
model.
of the pressure roller and (d)
the path of the nozzle and pressure roller in the outermost circle of the model.
3. Equipment and Experiment

3. Equipment
3.1. and for
The Equipment Experiment
Printing CCFRP
As shown
3.1. The Equipment in Figure 6a, the
for Printing 3D printer for printing CCFRPs consists of its structure, hardware,
CCFRP
and a computer. The computer sends instructions, the hardware accepts instructions, and the structure
As shown
executes in Figure
instructions. 6a, the
Figure 6b 3D printer
shows the for
coreprinting CCFRPs
components thatconsists
perform of the
its structure,
function of hardware,
feeding,
and a computer.
cutting, rotating, and Thepressurizing.
computer sendsFigureinstructions,
6c, shows hethe hardware
prepared accepts
CCFRPs instructions,
of which and the
the diameter is
structure executes instructions. Figure 6b shows the core components that perform
0.58 mm. Figure 6e shows the details of the nozzle and the pressure roller. The pressure roller can the function of
feeding,
lift cutting,
and drop rotating,
accurately andthe
under pressurizing. Figure
control of a ball 6c, and
screw, showsthehe prepared
pressure can CCFRPs
be adjusted of which the
by setting
diameter is 0.58mm. Figure 6e shows the details of the nozzle and the pressure
the distance of the pressure roller lower than the nozzle. Furthermore, two heating rods are used to roller. The pressure
rollerthe
heat can lift and
nozzle anddrop
the accurately under
pressure roller inthe
thecontrol
device.of a ball
The heatscrew,
in theand the can
nozzle pressure
softencanthebe adjusted
polymeric
by setting
matrix in thetheCCFRPs
distancesoofthat
thethe
pressure
CCFRPs roller
can lower than
be easily the nozzle.
deposited, andFurthermore,
the heat in the two heatingroller
pressure rods
are used to heat the nozzle and the pressure roller in the device. The heat in the
can keep the matrix in a molten state when pressurizing the part, which makes the adhesion between nozzle can soften the
polymeric matrix
the layers better. in the CCFRPs so that the CCFRPs can be easily deposited, and the heat in the
pressure roller can keep the matrix in a molten state when pressurizing the part, which makes the
adhesion between the layers better.
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Materials 2019, 12, x FOR PEER REVIEW 8 of 15

Figure 6. (a) The equipment for printing CCFRPs, (b) the nozzle device, (c) the prepared CCFRPs,
Figure 6. (a) The equipment for printing CCFRPs, (b) the nozzle device, (c) the prepared CCFRPs, (d)
(d) the diameter of CCFRPs and (e) the pressure roller.
the diameter of CCFRPs and (e) the pressure roller.
3.2. Printing Process Parameters
3.2. Printing Process Parameters
Printing the CCFRPs is different from printing the PLA. The feeding speed must be consistent
Printing the CCFRPs is different from printing the PLA. The feeding speed must be consistent with
with the nozzle moving speed to avoid the accumulation and breaking of CCFRPs and the speed must
the nozzle moving speed to avoid the accumulation and breaking of CCFRPs and the speed must be slow
be slow to ensure the rolling effect of pressure roller when printing the CCFRPs, the feeding speed and
to ensure the rolling effect of pressure roller when printing the CCFRPs, the feeding speed and the
the moving speed is 20 mm/min. The material diameter is 0.58 mm; layer thickness is set to 0.2 mm
moving speed is 20 mm/min. The material diameter is 0.58 mm; layer thickness is set to 0.2 mm to
to increase adhesion between layers. In this paper, 1k carbon fiber is used to prepare the composite
increase adhesion between layers. In this paper, 1k carbon fiber is used to prepare the composite
material, and the fiber content is 10.3%. Setting the printing parameters is crucial for printing CCFRPs
material, and the fiber content is 10.3%. Setting the printing parameters is crucial for printing CCFRPs
and CURA is used to slice the part in this article. The multi-process parameters of printing are specified
and CURA is used to slice the part in this article. The multi-process parameters of printing are specified
as the Table 2.
as the Table 2.
Table 2. The parameters of printing CCFRPs.
Table 2. The parameters of printing CCFRPs.
Parameter Amount
Parameter Amount
Nozzle diameter
Nozzle diameter 0.8 mm
0.8 mm
Material diameter
Material diameter 0.58 mm
0.58 mm
Feeding speed 20 mm/min
Feeding speed 20 mm/min
Moving speed 20 mm/min
Moving speed 20 mm/min
Rotating speed 2 rad/s
Rotating
Layer speed
thickness 20.2
rad/s
mm
Layer thickness
Infill percentage 0.2 mm
100%
Infill
Fiberpercentage
content 100%
10.3%
Fiber temperature
Extrusion content 200 ◦ C
10.3%
Extrusion
Pressure temperature
roller temperature 200 ◦C
180 °C
Pressure roller temperature 180 °C

3.3. Path Experiment

 Materials 2020, 13, 471 9 of 15

3.3. Path Experiment

Materials 2019, 12, x FOR PEER REVIEW 9 of 15
Figure 7 shows the four states of the pressure roller when printing a build circle of paths with
Figure The
CCFRPs. 7 shows
path the four
of the states of
pressure the is
roller pressure roller
consistent withwhen printing
the path shown a build circle5cofand
in Figure paths
the with
angles
CCFRPs. The path of the pressure roller is consistent with the path shown in Figure 5c and
of rotation of the pressure roller are the same as the angles shown in Figure 5d. The pressure roller has the angles
of applied
rotationpressure
of the pressure roller are
on all CCFRPs the same
whether as the
the path of angles shown
pressure roller in
is aFigure
curve 5d.or aThe
line.pressure roller
The experiment
has appliedthe
explains pressure on all
correctness andCCFRPs whether
rationality of thethe path
path of pressure
processing of theroller is a roller.
pressure curve or a line. The
experiment explains the correctness and rationality of the path processing of the pressure roller.

Figure
Figure Thefour
7. 7.The fourstates
states of the
thepressure
pressureroller when
roller whenprinting a circle
printing of paths.
a circle (a) state
of paths. (a) before rotation;
state before
rotation; (b) state 1after θ rotation; (c) state3 after θ rotation; (d) state
(b) state after θ rotation; (c) state after θ rotation; (d) state after θ 4 after θ rotation.
rotation.

3.4. Strength Test

3.4. Strength Test
The tensile test model is designed and printed according to the standard GB/T1040.1-2006. The size
The tensile test model is designed and printed according to the standard GB/T1040.1-2006. The
diagram of the sample for the tensile test is shown in Figure 8a. The length of the sample is 150 mm,
size diagram of the sample for the tensile test is shown in Figure 8a. The length of the sample is 150
the width is 15 mm, the thickness is 2 mm and the tensile speed is 5 mm/min. The CCFRPs are closely
mm, the width is 15 mm, the thickness is 2 mm and the tensile speed is 5 mm/min. The CCFRPs are
aligned in the lengthwise direction. The printed sample of the tensile test is shown in Figure 8b.
closely aligned in the lengthwise direction. The printed sample of the tensile test is shown in Figure
Figure 8c shows the test machine. The bending test was carried out in the form of three-point bending,
8b. Figure 8c shows the test machine. The bending test was carried out in the form of three-point
according to the standard GB/T449:2005. The size of the sample for the three-point bending test is
bending, according to the standard GB/T449:2005. The size of the sample for the three-point bending
shown in the Figure 8d. The length is 80 mm, the width is 15 mm, the thickness is 3 mm, the bending
test is shown in the Figure 8d. The length is 80 mm, the width is 15 mm, the thickness is 3 mm, the
speed is 5 mm/min, and the three-point bending length is 50 mm. The CCF is closely aligned along the
bending speed is 5 mm/min, and the three-point bending length is 50 mm. The CCF is closely
length of the sample and is perpendicular to the direction of the bending. The printed sample is shown
aligned along the length of the sample and is perpendicular to the direction of the bending. The
in Figure 8e. Figure 8f,g shows the results of the tensile and bending strength test.
printed sample is shown in Figure 8e. Figure 8f,g shows the results of the tensile and bending
strength test.
 Materials 2020, 13, 471 10 of 15

Materials 2019, 12, x FOR PEER REVIEW 10 of 15

(a) (b) (c)

(e)
(d)

(f) (g)

Figure
Figure (a)(a)
8. 8. TheThe model
model ofof the
the tensile
tensile test
test (unit:
(unit: mm),
mm), (b)(b)
thethe printed
printed sample
sample ofof the
the tensile
tensile test,
test, (c)(c) the
the
testmachine,
test machine,(d)(d)the
themodel
model ofof the
the bending
bendingtest,test,(e)
(e)the
theprinted
printed sample of the
sample bending
of the test,test,
bending (f) the
(f) result
the
of the tensile test, and (g) the result of the bending test.
result of the tensile test, and (g) the result of the bending test.

4. Results and Discussion

4. Results and Discussion
4.1. Pressure Path Analysis
4.1. Pressure Path Analysis
The schematic diagram of the pressurized printing of CCFRPs is shown in Figure 9c. The distance
The schematic
between the nozzlediagram of the pressurized
and the platform is 0.2 mm soprinting
that the of CCFRPs
CCFRPs stayiscontinuous
shown in and Figure 9c. to
adhere Thethe
distance between the nozzle and the platform is 0.2 mm so that the CCFRPs stay
platform during printing. The CCFRPs are laid on the platform by their own weight and the adhesion continuous and
adhere
betweento the
the platform during
thermoplastic andprinting. The CCFRPs
the platform. The partare laid on
printed the platform
without pressureby is their
shown own weight9a.
in Figure
and the adhesion between the thermoplastic and the platform. The part printed
The CCFRPs in one layer are bonded together by PLA. There are gaps between the CCFRPs without without pressure is
shown in Figure
applying 9a.on
pressure The CCFRPs
part, in one
resulting layer areadhesion
in reducing bonded together by PLA.
of CCF. The There
pressure areisgaps
roller lowerbetween
than the
the CCFRPs without applying pressure on part, resulting in reducing adhesion of CCF.
nozzle and can press the parts. Pressure allows the CCF to collapse and expand, extruding the excess The pressure
roller
PLA is lower
from the than the and
CCFRPs nozzle and can
applying thepress
excessthe
PLAparts. Pressure
on the allows
expanded CCF.the CCF 9b
Figure to shows
collapse
theand
part
expand, extruding the excess PLA from the CCFRPs and applying the excess PLA on
printed in accordance with the path shown in the Figure 5. This process can increase the cross-linking the expanded
CCF. Figure 9b shows the part printed in accordance with the path shown in the Figure 5. This
process can increase the cross-linking of CCF and the strength of the model, and the validity of the
algorithm of pressure roller is verified. Pressurization is a compaction process that can reinforce the
Materials 2020, 13, 471 11 of 15

of CCF 2019,
Materials and 12,
thex strength
FOR PEER of the model,
REVIEW and the validity of the algorithm of pressure roller is verified.
11 of 15
Pressurization is a compaction process that can reinforce the cross-linking of inter-laminar CCFRPs
cross-linking of inter-laminar
and the adhesion CCFRPs
of the adjacent layer ofand the adhesion
CCFRPs, of the of
so the strength adjacent layerbeofincreased.
model can CCFRPs, so the
strength of model can be increased.

Figure 9.
9. The
Theprinting
printingmodel
model without
without pressure
pressure (a) with
(a) and and with pressure
pressure (b),
(b), and (c) and (c) the schematic
the schematic diagram
of the pressurized
diagram printing CCFRPs.
of the pressurized printing CCFRPs.

4.2. Tensile
4.2. Tensile Strength
Strength and
and Bending
Bending Strength
Strength Analysis
Analysis
The results
The results of
of the
the tensile
tensile test
test and
and the the bending
bending testtest of
of the
the models
models printed
printed byby PLA,
PLA, CCFRPs,
CCFRPs,
CCFRPs1, CCFRPs3, and CCFRPs5 are shown in Figure 10. The model
CCFRPs1, CCFRPs3, and CCFRPs5 are shown in Figure 10. The model printed with CCFRPs1 means printed with CCFRPs1 means
that the pressure roller is 0.1 mm lower than the nozzle when printing the model.
that the pressure roller is 0.1 mm lower than the nozzle when printing the model. The model printed The model printed
with CCFRPs3
with CCFRPs3 means
means thatthat the
the pressure
pressure roller
roller is
is 0.3
0.3 mm
mm lower
lower than
than the
the nozzle
nozzle when
when printing the
printing the
model. The model printed with CCFRPs5 means that the pressure roller
model. The model printed with CCFRPs5 means that the pressure roller is 0.5 mm lower than the is 0.5 mm lower than the
nozzle when printing the model. The tensile strength of the model printed with
nozzle when printing the model. The tensile strength of the model printed with PLA is only 42.76 PLA is only 42.76 MPa.
The tensile
MPa. strength
The tensile of the model
strength of theprinted
model with CCFRPs
printed is 109.9 MPa,
with CCFRPs which
is 109.9 shows
MPa, thatshows
which the strength of
that the
PLA is improved by CCF. However, the reinforced effect is not obvious and cannot
strength of PLA is improved by CCF. However, the reinforced effect is not obvious and cannot exert exert the excellent
reinforced
the performance
excellent reinforced of CCF. The three
performance models
of CCF. Theprinted under different
three models printed pressures are tested
under different to analyze
pressures are
the effect of pressure on strength. The strength of the model printed with CCFRPs1
tested to analyze the effect of pressure on strength. The strength of the model printed with CCFRPs1 is 291.56 MPa,
and
is the strength
291.56 MPa, andis increased by 682%
the strength comparedby
is increased to682%
PLA. It means thetopressure
compared PLA. Itismeans
crucialthein the printing
pressure is
of CCFRPs and can enhance the cross-linking and adhesion of CCFs inside the
crucial in the printing of CCFRPs and can enhance the cross-linking and adhesion of CCFs inside the model. Pressure can
enhancePressure
model. printingcan
greatly and ensure
enhance printingthegreatly
excellent
andreinforced
ensure theperformance of the CCFs.
excellent reinforced The strength
performance of
of the
the models printed by CCFRPs3 and CCFRP5s are 491.76 MPa and 644.8
CCFs. The strength of the models printed by CCFRPs3 and CCFRP5s are 491.76 MPa and 644.8 MPa,MPa, representing increases
of 1150% and increases
representing 1508% compared
of 1150% to PLA, respectively.
and 1508% comparedIt means that the
to PLA, strength of Itthemeans
respectively. modelthat printed
the
with CCFRPs can be enhanced by increased pressure, and the effect is obvious.
strength of the model printed with CCFRPs can be enhanced by increased pressure, and the effect is
obvious.
 Materials 2020, 13, 471 12 of 15
Materials 2019, 12, x FOR PEER REVIEW 12 of 15

Figure
Figure10.
10.The
Thetensile
tensilestrength
strengthand
andbending
bendingstrength
strengthofofparts
partsunder
underdifferent
differentpressures.
pressures.

Thebending
The bendingstrength
strengthofofthe
themodel
modelprinted
printedwithwithPLA
PLAisis68.64
68.64MPa.
MPa.The Thebending
bendingstrength
strengthofofthe
the
modelprinted
model printed with
with CCFRP
CCFRPisis163.13 MPa—an
163.13 MPa—an increase of 238%
increase compared
of 238% comparedto PLA.
to The
PLA.bending strength
The bending
of the models
strength of theprinted
modelswith CCFRP1,
printed withCCFRP3,
CCFRP1,and CCFRP5and
CCFRP3, are CCFRP5
256.76 MPa, are357.43
256.76MPa,MPa,and 401.24MPa,
357.43 MPa,
representing
and 401.24 MPa,increases of 374%,
representing 521%, and
increases 585% compared
of 374%, 521%, andto585%PLA,compared
respectively, as shown
to PLA, in Figureas
respectively, 10.
The above
shown data show
in Figure that
10. The the bending
above data showstrength of models
that the bendingafter pressurization
strength of modelsisafter
significantly improved
pressurization is
and the greater
significantly the pressure,
improved and thethegreater
better the
theeffect of CCF
pressure, reinforcement.
the better the effectThe of
results
CCF show that the error
reinforcement. Theof
each experiment
results show that isthewithin
error10%, which
of each proves that
experiment is the experiment
within is repeatable.
10%, which proves that the experiment is
However, excessive pressure will dislocate the CCFs. As shown in Figure 11, the model printed
repeatable.
withHowever,
CCFRPs5excessive
is deformed due towill
pressure excessive pressure.
dislocate The As
the CCFs. CCF is pulled
shown up due
in Figure 11,tothe
excessive
model pressure,
printed
which
with destroysisthe
CCFRPs5 surface quality
deformed due to of model. Furthermore,
excessive pressure. Thethe CCFmodel cannotupbedue
is pulled formed when we
to excessive
increase the
pressure, whichpressure of the
destroys thepressure
surface roller
qualitybased on printing
of model. the modelthe
Furthermore, with CCFRPs5.
model cannotAlthough
be formed the
strength
when we is increased,
increase the the surface
pressure ofquality and dimensional
the pressure roller based accuracy of model
on printing is reduced.
the model with CCFRPs5.
Although the strength is increased, the surface quality and dimensional accuracy of model is
reduced.
Materials 2020, 13, 471 13 of 15

Materials 2019, 12, x FOR PEER REVIEW 13 of 15

CCFRPs1 CCFRPs3 CCFRPs5

Figure 11. The models printed by CCFRPs1, CCFRPs3 and CCFRPs5.

Figure 11. The models printed by CCFRPs1, CCFRPs3 and CCFRPs5.

5. Conclusions
Conclusions
FDM has hasbeenbeen investigated
investigated as a low-cost
as a low-cost manufacturing
manufacturing method for method for fiber-reinforced
fiber-reinforced composites
composites
and there areandmany there are many
studies on thisstudies
subjecton this subject
currently. currently.
For the manufacture For the manufacture
of CCFRP of CCFRP
parts, pressure is
parts, pressure is essential. Without pressure, the CCFRPs between adjacent
essential. Without pressure, the CCFRPs between adjacent layers are adhered by the thermoplastic layers are adhered by
the thermoplastic
during the printing, during
CCFRP the printing,chains
molecular CCFRP molecular
of two adjacent chains
layersofdotwonot adjacent
diffuse, andlayers
the do not
degree
diffuse, and will
of diffusion the degree
affect theof diffusion will affect
binding strength of the binding
parts. The strength of theand
traditional parts. The traditional
mature technologyand for
mature technology
manufacturing CCFRPs for manufacturing
is AFP, which uses CCFRPs is AFP, which
a consolidation usesana autoclave
roller and consolidation
process roller and an
to improve
autoclave
the qualityprocess
of part.toCompared
improve the quality
to AFP, FDM ofispart. Compared
simple in designtoand AFP, FDM is but
operation simple
lacksinthe
design and
ability to
operation but lacks the ability to apply pressure and heat to the model.
apply pressure and heat to the model. This work proposed a molding process for printing CCFRPs to This work proposed a
molding
combine the process for printing
advantages of FDMCCFRPs
and AFP.to combine
A novel the advantages
3D-printing structureof forFDM
CCFRPs andis AFP. A novel
put forward in
3D-printing structure
this article, which can for
heatCCFRPs is put forward
and pressurize the CCFRPsin this article,
with whichroller
a pressure can heat andprinting.
during pressurize the
Using
CCFRPs with
this process, thea CCFRPs
pressureare roller during printing.
pressurized Usingtothis
while printing process,
increase the CCFRPs
the bond between are pressurized
layers. Then the
while
strengthprinting to increase
of printed model with the bond betweenprocess
this molding layers.isThen
tested.theThestrength
detailsofareprinted model with this
as follows:
molding process is tested. The details are as follows:
1. Seven movements (X, Y, Z, F, C, R, L) in the molding process of printing CCFRP are coordinated
to complete
1. Seven movementsthe printing.
(X, Y, Z, The
F, C,pressure roller
R, L) in the is rotated
molding and lifted
process to apply
of printing pressure
CCFRP and heat to
are coordinated
the part.
to complete the printing. The pressure roller is rotated and lifted to apply pressure and heat to
2. theThe path of pressure roller is sometimes different to that of the nozzle. Any curved path of
part.
pressure
2. The path of roller needsroller
pressure to beisconverted
sometimes to different
a straighttopaththat toof prevent jittering
the nozzle. Any and to improve
curved path of
efficiency.
pressure Then,
roller needsthe to
rotation angle oftothe
be converted pressurepath
a straight rollertoisprevent
calculated basedand
jittering on the straight
to improve
path. TheThen,
efficiency. accuracy of path angle
the rotation processing
of the for pressure
pressure roller
roller has been based
is calculated provedonbythe thestraight
experiment.
path.
The phenomenon shows that pressure can enhance the CCF bonding.
The accuracy of path processing for pressure roller has been proved by the experiment. The
phenomenon shows that pressure can enhance the CCF bonding.
3. The tensile and bending strength of models printed by CCFRPs with different levels of pressure
have been tested to analyze the effect of pressure. The results show that pressure has a
Materials 2020, 13, 471 14 of 15

3. The tensile and bending strength of models printed by CCFRPs with different levels of pressure
have been tested to analyze the effect of pressure. The results show that pressure has a significant
effect on the reinforcement of CCF on PLA. The tensile strength and bending strength of the
model are enhanced to 644.8 MPa and 401.24 with increased pressure. The results show that the
error of each experiment is within 10%, which proves that the experiment is repeatable. However,
excessive pressure will destroy the path of the CCFs and the surface quality of model, and may
even lead to printing failure.

It can be seen that pressure is necessary for printing CCFRP with FDM. This work will provide
the technical foundations for printing CCFRPs with FDM.

Author Contributions: Conceptualization, Z.Z.; methodology, Y.T; data curation, Y.T.; writing—original draft
preparation, J.Z.; writing—review and editing, F.Z.; funding acquisition, B.Y. All authors have read and agreed to
the published version of the manuscript.
Funding: This research was funded by the fundamental research funds for the central universities (NO. 175104003,
WUT: 2018III065GX, WUT: 2019IVA051)” and the national key R&D program of China (No. 2017YFB1303703)”.
Conflicts of Interest: The authors declare no conflict of interest.

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