Characterization and Finite Element Analyses of Tensile and Bending Behavior of Nylon Reinforced with Continuous Carbon Fiber Produced by Additive Manufacturing

Abstract Leveraging advancements in extrusion technology, continuous filament fabrication (CFF) offers a cutting-edge approach to producing composite components layer by layer. What sets this technique apart is its ability to apply reinforcements precisely where needed, optimizing both performance and sustainability. The adopted approach to depositing the fiber using a reinforced filament is critical in determining the final characteristics. Despite its potential, there is limited understanding of mechanical performance, particularly under bending conditions and when only a few reinforced layers are used. This study investigates the mechanical behavior of CFF-produced composite materials under tensile and bending loads. Reinforced samples were fabricated and tested under varying conditions, such as fiber orientation, number of reinforcement layers, and placement along the build direction. The localized reinforcement capability of CFF highlights the importance of numerical modeling in virtually testing structures before production. To this end, the experimental results were replicated in a numerical environment, enabling precise calibration of a finite element model to predict the mechanical behavior of reinforced components.