Multiplanar continuous fiber reinforcement in additively manufactured parts via co-part assembly

Purpose Many additively manufactured parts suffer from reduced interlayer strength. This anisotropy is necessarily tied to the orientation during manufacture. When individual features on a part have conflicting optimal orientations, unavoidably compromised. paper aims demonstrate strategy in which can be functionally separated into “co-parts” are individually aligned an orientation, selectively reinforced with continuous fiber, printed simultaneously and, finally, assembled composite substantially improved performance. Design/methodology/approach Several candidate were selected for co-part decomposition. They as standard fused filament fabrication plastic parts, fiber one plane and assemblies both without reinforcement (CFR). All loaded until failure. Additionally, representative of common suboptimally oriented (“unit tests”) similarly tested. Findings CFR delivered substantial improvement over unreinforced plastic-only assemblies, expected. Reinforced held up 2.5x ultimate load equivalent parts. The even greater improvement, particularly when also fiber. Plastic-only 3.2x only Continuous 6.4x thought process behind general design explored vision simulation-driven automated implementation discussed. Originality/value technique novel way overcome most challenges preventing functional use It delivers compelling performance carbon 3D Further study could extend any anisotropic manufacturing method, additive or otherwise.