Enhancing the Interlaminar Shear Strength and Void Control of 3D-Printed Continuous Carbon-Fiber-Reinforced Polymer Composites Using a Robotic Magnetic Compaction Force-Assisted Additive Manufacturing (MCFA-AM) Process and Carbon-Nanofiber Z-Threads

Three-dimensional (3D) printing with continuous carbon-fiber-reinforced polymer (C-CFRP) composites is under increasing development, as it offers more versatility than traditional molding processes, such the out-of-autoclave-vacuum bag only (OOA-VBO) process. However, due to layer-by-layer deposition of materials, voids can form between layers and weaken some parts’ properties, interlaminar shear strength (ILSS). In this paper, a novel mold-less magnetic compaction force-assisted additive manufacturing (MCFA-AM) method was used print carbon nanofiber (CNF) z-threaded CFRP (ZT-CFRP) laminates significantly improved ILSS reduced void content compared C-CFRP laminates, which are printed using no-pressure 3D-printing process (similar fused-deposition-modeling process). The radial flow alignment (RFA) resin-blending techniques were utilized manufacture printing-compatible fast-curing ZT-CFRP prepreg tape act feedstock for MCFA-AM printhead, mounted on robotic arm. terms ILSS, coupled nanomaterial technology outperformed made both OOA-VBO Furthermore, doubled production speed This demonstrates that through integration new nanomaterials techniques, paradigm shift in better performance, versatility, agility, efficiency, lower cost achievable.