Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation
Material extrusion is currently the primary method for manufacturing fibre-reinforced polymer composites. However, its limitations in extrusion force and material selection restrict its broader application. In this study, a screw-based online mixing extrusion system was developed for carbon fibre-re...
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| Format: | Article |
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2024.2441964 |
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| author | Siwei Lu Yunze Wang Beining Zhang Jincang Bai Chuncheng Yang Yi Cao Changning Sun Dichen Li |
| author_facet | Siwei Lu Yunze Wang Beining Zhang Jincang Bai Chuncheng Yang Yi Cao Changning Sun Dichen Li |
| author_sort | Siwei Lu |
| collection | DOAJ |
| description | Material extrusion is currently the primary method for manufacturing fibre-reinforced polymer composites. However, its limitations in extrusion force and material selection restrict its broader application. In this study, a screw-based online mixing extrusion system was developed for carbon fibre-reinforced polyether-ether-ketone composites. The extrusion screw design was optimised using numerical simulation to enhance the mechanical properties of the printed parts. Simulation results indicated that the length of the metering section and the pitch have the greatest impact on extrusion pressure, while pin diameter and height significantly affect the mixing quality. The optimised screw with pins led to a 34% increase in extrusion pressure and a 73% enhancement in mixing degree, compared to that of the initial screw. Mechanical testing revealed that composite specimens produced with the optimised pin screw exhibited 27%, 36%, and 63% improvements in tensile strength, flexural strength, and interlayer shear strength, respectively, over those produced with the initial screw. Microscopic analysis showed that the enhanced performance was attributed to better interlayer bonding and improved fibre dispersion. This study presents a new paradigm for screw configuration design for screw extrusion-based 3D printing systems. |
| format | Article |
| id | doaj-art-bdd3b07bbaab44f39a3bc3f6330d28f4 |
| institution | DOAJ |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-bdd3b07bbaab44f39a3bc3f6330d28f42025-08-20T02:39:47ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2024.2441964Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisationSiwei Lu0Yunze Wang1Beining Zhang2Jincang Bai3Chuncheng Yang4Yi Cao5Changning Sun6Dichen Li7State Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaState Key Laboratory for Manufacturing System Engineering, School of Mechanical Engineering, Xi’an Jiaotong University, Xi’an, People’s Republic of ChinaMaterial extrusion is currently the primary method for manufacturing fibre-reinforced polymer composites. However, its limitations in extrusion force and material selection restrict its broader application. In this study, a screw-based online mixing extrusion system was developed for carbon fibre-reinforced polyether-ether-ketone composites. The extrusion screw design was optimised using numerical simulation to enhance the mechanical properties of the printed parts. Simulation results indicated that the length of the metering section and the pitch have the greatest impact on extrusion pressure, while pin diameter and height significantly affect the mixing quality. The optimised screw with pins led to a 34% increase in extrusion pressure and a 73% enhancement in mixing degree, compared to that of the initial screw. Mechanical testing revealed that composite specimens produced with the optimised pin screw exhibited 27%, 36%, and 63% improvements in tensile strength, flexural strength, and interlayer shear strength, respectively, over those produced with the initial screw. Microscopic analysis showed that the enhanced performance was attributed to better interlayer bonding and improved fibre dispersion. This study presents a new paradigm for screw configuration design for screw extrusion-based 3D printing systems.https://www.tandfonline.com/doi/10.1080/17452759.2024.2441964Screw configurationonline mixingoptimisationmaterial extrusionCF/PEEK composites |
| spellingShingle | Siwei Lu Yunze Wang Beining Zhang Jincang Bai Chuncheng Yang Yi Cao Changning Sun Dichen Li Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation Virtual and Physical Prototyping Screw configuration online mixing optimisation material extrusion CF/PEEK composites |
| title | Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| title_full | Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| title_fullStr | Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| title_full_unstemmed | Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| title_short | Enhancing interlayer bonding and fibre dispersion of fibre-reinforced polyether-ether-ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| title_sort | enhancing interlayer bonding and fibre dispersion of fibre reinforced polyether ether ketone composites prepared by online mixing extrusion through screw configuration optimisation |
| topic | Screw configuration online mixing optimisation material extrusion CF/PEEK composites |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2024.2441964 |
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