Additive Manufacturing/ 3D Printing Using Composites
Additive manufacturing, commonly known as 3D printing, has revolutionized composite production by enabling the layer-by-layer construction of intricate composite structures. In the realm of composites, additive manufacturing techniques allow for the creation of complex geometries with precise fiber orientations and resin distribution, optimizing material performance. This technology offers the flexibility to customize parts, reduce waste, and experiment with novel composite combinations. By depositing materials layer upon layer, additive manufacturing facilitates the production of lightweight, high-strength components tailored for specific applications in industries such as aerospace, automotive, and healthcare, pushing the boundaries of what's achievable in composite design and fabrication.
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Materials & Processes: Fabrication methods
There are numerous methods for fabricating composite components. Selection of a method for a particular part, therefore, will depend on the materials, the part design and end-use or application. Here's a guide to selection.
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How to validate 3D-printed composite part performance
Integrated Computational Materials Engineering (ICME) workflow simulates composite material performance to speed development, optimize performance and reduce costs for a redesigned 3D-printed CFRP bracket.
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Contactless measurement of temperature, pressure in composites
Magnetic microwires enable contactless measurement of temperature and pressure during cure and in service.
WatchKnowledge Centers
During CW Tech Days: Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.
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CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.
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This CW Tech Days event will explore the technologies, materials, and strategies that can help composites manufacturers become more sustainable.
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Latest Additive Manufacturing News And Updates
9T Labs webinar presents continuous carbon fiber advancements
Free online webinar offered on June 19 breaks down research into latest technologies and methodologies by 9T Labs and Purdue University experts.
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GZero expands FFF 3D printing capabilities to second location
GZero opens another location in West Chester, Ohio, to optimize the production of fiber-reinforced 3D printed parts for service bureau customers.
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Diehl Aviation, 9T Labs present Eco Bracket
Ultra-lightweight and made of recycled composites, the Eco Bracket cuts weight and cost in half and reduces CO2 emissions, in addition to providing high performance.
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Xenia presents carbon fiber-reinforced PVDF compounds functionalized for 3D printing
3D printing materials portfolio now extends from unfilled PVDF to carbon-fiber-reinforced PVDF, adding to the end product’s high performance and chemical resistance.
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Formula 1 team adopts Roboze 3D printed composites
The Visa Cash App RB Formula 1 team is collaborating with Roboze to reduce weight and create parts with complex geometries via carbon fiber/PEEK.
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Composite accelerator pedal enhances Formula SAE performance
Venox Systems was brought into the fold to deliver a 3D printed continuous carbon fiber/PEKK pedal for the TU Wien Racing Team that exceeded its aluminum counterpart.
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Featured Posts
Reinforcing hollow, 3D printed parts with continuous fiber composites
Spanish startup Reinforce3D’s continuous fiber injection process (CFIP) involves injection of fibers and liquid resin into hollow parts made from any material. Potential applications include sporting goods, aerospace and automotive components, and more.
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Industrializing additive manufacturing in the defense/aerospace sector
GA-ASI demonstrates a path forward for the use of additive technologies for composite tooling, flight-qualified parts.
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Eaton developing carbon-reinforced PEKK to replace aluminum in aircraft air ducts
3D printable material will meet ESD, flammability and other requirements to allow for flexible manufacturing of ducts, without tooling needed today.
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The next evolution in AFP
Automated fiber placement develops into more compact, flexible, modular and digitized systems with multi-material and process capabilities.
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Multi-material, self-sensing, 3D-printed scoliosis braces
Startup Fited and Brightlands Materials Center have developed a lighter weight, thinner CFRP corrective brace, including pressure sensors made from continuous carbon fibers.
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Increased molding productivity via additive manufacturing
Companies in multiple segments turn to 3D printing for end-of-arm tools, fixtures for increased safety and functionality, lower cost and faster turnaround times.
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FAQ: Additive Manufacturing
What is additive manufacturing in composites?
Additive manufacturing, also known as 3D printing, in composites involves the layer-by-layer deposition of composite materials, such as continuous fibers or chopped fibers within a matrix, to create complex parts or structures.
What types of additive manufacturing methods are used for composites?
Various methods are employed, including Fused Filament Fabrication (FFF), Continuous Fiber 3D Printing (CFF), Binder Jetting, Directed Energy Deposition (DED), and others that selectively deposit materials to build composite parts.
What composite materials can be used in additive manufacturing?
Additive manufacturing processes can work with a range of composite materials, such as carbon fiber-reinforced polymers (CFRPs), glass fiber composites, and even advanced materials like nanocomposites or hybrid composites.
What is Formnext Chicago?
Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois.
Formnext Chicago is part of a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).
Here is the full lineup of Formnext events in North America:
- Formnext Forum Austin took place in August 2023 and will return to Texas in 2026.
- Additive Manufacturing Sector Powered by Formnext at IMTS in 2024
- Formnext Chicago in 2025
What are the advantages of additive manufacturing in composites?
Benefits include the ability to create complex geometries, lightweight structures, reduced material waste, customization, rapid prototyping, and the integration of functional features within parts.
Are there limitations to additive manufacturing in composites?
Challenges include limitations in scaling for large-scale production, post-processing requirements, ensuring consistent mechanical properties, and the need for advancements in material options.
