Additive Manufacturing of Composite Materials

Additive Manufacturing (AM) is a smart development manufacturing technique defined as the process of joining materials to make three-dimensional objects from a Computer Aided Design (CAD) model, usually layer by layer. Some common automated techniques such as Stereolithography (SLA), Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS) and Laminated Object Manufacturing (LOM) have been highlighted in recent research, rang- ing from parts created for orthopaedic implants using bioprinting to fiber reinforced composites used in automotive and aerospace industries. An im- portant issue with AM is the limitation of available materials with adequate structural capacity. Current common materials such as Acrylonitrile Buta- diene Styrene (ABS) and Polyactic Acid (PLA) are not robust enough to be used in applications where high strength is required. Thus, using compos- ite materials allows us to combine two or more materials with the desired properties that cannot be provided by conventional metal alloys, ceramics, or polymers. In recent years some companies have developed processes to incorporate composites into AM, such as carbon fiber reinforced filaments used in FDM process and creation of metal-plastic parts using hybrid pro- cesses. However there are some limitations about materials and performance to overcome, including high potential for delamination between the printed layers, void formation, increased curing time, modeling and simulation, in case of fiber reinforced composite, low fiber content. The development and commercialization of AM technology to create composites parts with similar properties obtained by conventional methods are the main scope of researches in this area nowadays. Therefore, this study has the proposal of investigate AM techniques of composite materials, using different types of reinforcement and matrix. During this work different methods of AM will be discussed as well as the difference between properties obtained with conventional methods. It is noted that AM of composites using metal matrix are already used in practical application due to high properties obtained and that polymer composites still need to overcome some challenges. However, with the in- tense researches being done, in near future these materials will be able to compete with conventional composites fabrication.