Experimental Analysis and Optimisation of a Novel Laser-Sintering Process for Additive Manufacturing of Continuous Carbon Fibre-Reinforced Polymer Parts

Additive manufacturing of continuous carbon fibre-reinforced polymer (CCFRP) parts enables the production high-strength for aerospace, engineering and other industries. Continuous fibres allow to be reinforced along load path, multiplying their mechanical properties. However, current additive processes producing CCFRP do not optimally meet requirements matrix. With resin- extrusion-based processes, time-consuming costly post-processing required remove support structures severely limits design freedom, small batches requires increased effort. In contrast, laser sintering has proven a promising alternative in an industrial environment, allowing robust without time-efficient economical manner single small-batch production. Based on novel laser-sintering machine with automated integration fibres, combination advantages process is achieved. This paper describes experimental analysis optimisation this using experiments. The processing time fibre could reduced by factor three compared initial state.