Development of a print head for non-planar additive manufacturing of carbon fiber-reinforced polymers

Abstract In order to realize the potential of high-performance lightweight parts manufactured using the combination of Fused Filament Fabrication (FFF) and Carbon Fiber Reinforced Polymers (CFRP), two main challenges have been identified for a print head design intended for load-oriented non-planar printing. To address these objectives of enabling dynamic layer height variation and fiber cutting, all while avoiding collisions in the printing system, this work presents the methodological development of a new specialized print head. By analyzing the process and taking the existing non-planar printing system into account, the relevant optimization parameters are identified and accurately defined. The methodological development is aligned with the VDI standard 2221 and includes a formal requirement analysis, parameter definition, and functional structure. The solution space is discussed and partial solutions are compared in detail, before the integration and final design are presented. The print head is physically realized, functionally verified by printing CFRP parts, and shown to fulfill all set requirements. Minor necessary changes during the manufacturing and construction of the system are discussed. Finally, the insight, definition, process analysis, and final version are employed to present a further optimized design with a concrete methodological outlook on enabling the load-oriented non-planar FFF of CFRP with this new highly optimized design.