Design and Analysis of Hybrid Fused Filament Fabrication Apparatus for Fabrication of Composites

Background: Additive manufacturing is the most recognized technology which uses metals, polymer, ceramics, and composites for fabrication with a layer-by-layer deposition strategy. Due to its lower cost, higher accuracy, and less material wastage, this technology is used for engineering and domestic applications. But in many applications, there is a need to alter the properties of the product in a specific direction with the help of some reinforcements. With reinforcements, composite layers can be fabricated using additive manufacturing techniques, which will enhance the directional properties. A novel apparatus is designed to spray the reinforcement material into the printed structures quickly and precisely. This spray nozzle is fully automated, which works according to toolpaths generated by slicing software. The alternate deposition of layers of reinforcement and build materials helped to fabricate customized composite products. Objective: This study aims to design and analyze the working principle of a novel composite manufacturing technique that has been developed to fabricate composite materials using additive manufacturing. The apparatus is numerically controlled by computer according to CAD data, which facilitates the deposition of alternate reinforcement and matrix material layers. The major challenges during the design process and the functioning of each component have been explored. Methods: The design process is initiated after a comprehensive literature review is performed to study previous composite manufacturing processes. The recent patents published by different patent offices of the world are studied in detail, and analysis has been used to design a low-cost composite fabrication apparatus. A liquid dispensing device comprises a storage tank attached with a pump and microprocessor. The microprocessor receives the signal from the computer as per tool paths generated by slicing software which decides the spray of reinforcements on polymer layers. The spraying apparatus moves in coordination with the primary nozzle of the Fused Filament Fabrication process. Results: The hybridization of the Fused Filament Fabrication process with the metal spray process has been successfully performed. The apparatus facilitates the fabrication of low-cost composite materials and the flexibility of complete customization of the composite manufacturing process. Conclusion: The anisotropic behavior of products can be easily controlled and managed during fabrication which can be used for different applications.