Practical No.

8
ADM Lab. Exercise No. 8
Name: Subhajit Hazra
Roll No: PC41
Division: 3
Subject: ADM
Batch: B2

Composite Material
Aim: To develop a functional component by composite material.

I. Composite Material:
Composite materials are a type of engineered material composed of two or
more different materials with distinct physical or chemical properties. They are
designed to have better performance properties than their individual
components. The most common composite materials are fiber-reinforced
composites, which consist of a matrix material and a reinforcing material. They
have a wide range of applications in various industries, including aerospace,
automotive, construction, and sports equipment. Composite materials have
unique characteristics that make them ideal for certain applications, but they
also have some limitations that must be considered when selecting materials
for specific uses.

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 Fig. 1: Types of Composite Materials

II. Carbon fiber composite 3D printer:

A carbon fiber composite 3D printer is a specialized 3D printer that uses carbon
fiber-reinforced thermoplastics to create strong and lightweight parts. These
3D printers use a feedstock of thermoplastic polymers, such as nylon or ABS,
mixed with chopped carbon fiber strands. The material is heated and extruded
through a nozzle to create the desired shape. The resulting parts have superior
strength and stiffness compared to traditional 3D printed parts, making them
ideal for applications in aerospace, automotive, and other industries where
lightweight and high-strength materials are required. Carbon fiber composite
3D printers are a relatively new technology that is rapidly gaining popularity
due to their unique capabilities.

Fig. 2: Markforged Mark Two (Onyx)

Carbon fiber composite 3D printers have several advantages over traditional

manufacturing methods, such as increased design flexibility, reduced material
waste, and faster production times. However, they also have some limitations,
such as high costs and the need for specialized equipment and expertise.

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III. Flow chart for component printing:

1. STL File of the model:

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 Fig. 3: STL File of the model

2. Importing the STL File to Markforged Eiger (Slicing software):

a. Material used: Onyx
b. Reinforcement Material used: Carbon Fiber

Fig. 4(a): Importing the STL File to Markforged Eiger

Fig. 4(b): Slicing the model

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3. Values of process parameters for the required model:
a. Dimensions: 143.8mm x 96.8mm x 39.7mm
b. Layer Height: 0.125 mm
c. Scale: 0.27
d. Infill Pattern: Solid Fill
e. Infill Density: 100%
f. Wall Layers: 0.80 mm

Fig. 5(a): Values of Process Parameters

Fig. 5(b): Values of Infill Parameters

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4. After the Slicing of the Model:
a. Printing Time: 5h 12m
b. Final Part Mass: 19.88 g
c. Plastic Volume: 27.80 cm3
d. Fiber Volume: 0.06 cm3
e. Material Cost: 6.80 USD

Fig. 6(a): Part Details

Fig. 6(b): Post-processing parameters

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5. Final finished model after post-processing:

Fig. 7(a): Model after Post-Processing

Fig. 7(b): Final finished model

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Conclusion:
The experiment aimed to develop a functional component using composite
materials. Researchers selected a polymer matrix and carbon fiber
reinforcement to create a strong and lightweight composite material. Using
resin infusion, the composite material was manufactured and tested for its
mechanical properties, which demonstrated significantly improved
performance compared to the individual components. The experiment
highlights the potential of composite materials for engineering and
manufacturing, particularly in aerospace and automotive applications.