Session: 01-01 Polymers: Characterization and Mechanical Properties I

Paper Number: 93890

93890 - Fused Granulated Fabrication (Fgf) Processing Study for Novel Scflmpaek Recycled Material to Manufacture Aeronautic Structural Parts. 

New additive manufacturing (AM) technologies provide more efficient alternatives to conventional processing. Therefore additive manufacturing is gaining traction in applications which require complex geometries, such as industrial production, engineering, and medicine. Fused Granulated Fabrication (FGF) is an AM technology in which, thermoplastic polymer pellets are directly extruded layer-by-layer to manufacture parts with high precision and minimal material waste. Injection moulding (IM) is the traditional technology for FGF, in IM polymer granules are injected by pressure into a mould with the required geometry.

In this sense, ECO-CLIP (From Clean-Sky2, Large Passenger Aircraft – Platform 2) have developed a novel recycled 40wt% short CF/LMPAEK material from factory scrap that have been used to manufacture structural parts, clips and brackets, for Multi-Functional Fuselage Demostrator (MFFD). Brackets have been manufactured by IM and FGF as an alternative to conventional technics. These projects aim to replace metal with thermoplastic structures to lighten the aircraft fuselage contributing to a greener, more efficient, and competitive aeronautic industry.

In this sense, a technical study of the material processability has been made for FGF. The most important results are presented in this work, such as: fibre breakage caused by the spindle and the nozzle, carbon fiber percentage after and before processing, thermal behaviour and thermal induce history, mechanical properties such as compression, tensile and flexural behaviour, etc.

For this purpose, three different nozzle diameters (0.8, 1.2 and 1.5mm) were used to ensure processability, mechanical requirements and physical performance. Carrying out a direct comparison with the results achieved by IM.

Other PAEK’s have been process by FGF or traditional fused filament fabrication (FFF) for comparative proposes, this enables to places ECO-CLIP material within the framework of high-performance 3D printing materials and gives an overview of the differences between both technologies, for their use in the aeronautics field.

Presenting Author: Celia Martín-Pérez AIMEN

Presenting Author Biography: Celia Martín Pérez is a Juniour Researcher in the field of Polymer Science. She has been working for several national and international projects during the last years. Specialised in manufacturing and characterisation of new materials, specially thermoplastic composites, 3Dprinting filament production and injection moulding among others. She started working at AIMEN after graduating as a chemist 2 years ago.

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