Robust additive manufacturing of polymer composites for optimal part production

Additive manufacturing (AM) is increasingly used for spare parts and small series of end-use parts. AM is a digital and physical process with many advantages such as enabling innovative designs with short lead times. This project aims to tackle some of the remaining key challenges to using AM in an industrial context. The project focuses on material extrusion AM with fibre-reinforced thermoplastic polymer materials ("composite AM") with a special attention devoted to continuous fibre reinforcements, e.g. carbon fibres. These are rather new high-end AM processes for making parts with very high stiffness and strength relative to the density, which can exceed the performance of light metal alloys. The main objectives are to develop composite AM technology to produce parts with improved quality, repeatability, documentation and sustainability, and to predict mechanical performance with high fidelity. Critical R&D challenges include developing a system for in situ process monitoring and establishing material models to be used in industrial finite element analysis software. Importantly, material recycling of composite AM parts will also be demonstrated along with an estimation of the carbon footprint compared to conventional composite processing routes. The applicant, Fieldmade AS, was an early Norwegian adopter of AM technology with their innovative portable micro-factories. Their ambition through this project is to generate a deeper understanding of materials, reinforcement layout, processes and part quality to enable the production of parts for higher criticality levels than is currently possible. The results will improve Fieldmade's NOMAD LW, a mobile AM solution with a large sales potential including exports. The project will ultimately contribute to the development of knowledge-based industry in Norway by employing an interdisciplinary approach that merges expertise in AM, material science, mechanics modelling, sensorics and machine learning.

Additive manufacturing (AM) is increasingly used for spare parts and end-use parts in small series. AM is a digital and physical process chain which has many advantages, such as enabling innovative designs and fast lead times. However, there are also challenges when it comes to employing AM in an industrial context. This project addresses some of the key challenges. The project focuses on material extrusion AM with fibre-reinforced thermoplastic polymer materi-als ("composite AM"), in particular AM with continuous fibre reinforcement, e.g. carbon fibres. These are rather new high-end AM processes for making parts with very high stiffness and strength relative to the density. The strength can exceed that of aluminium alloys. The main objective is to develop technology for composite AM, in order to produce parts with improved quality, repeatability, documentation and sustainability, and to predict mechanical performance with high fidelity. Critical R&D challenges include developing a system for in-situ process monitoring, and establishing material models to be used in industrial finite element analysis software. Furthermore, material recycling of composite AM parts will be demonstrated. The applicant, Fieldmade AS, was one of the first Norwegian companies to utilise AM, with their innovative portable microfactories. Through this project, Fieldmade’s ambition is to generate a deeper understanding of materials, reinforcement layout, processes and part quality, to enable the production of parts for higher criticality levels than currently possible. The results will, in particular, be used to improve Fieldmade's NOMAD LW AM unit which has a large sales potential, in particular for export. The project employs an interdisciplinary approach, combining expertise in additive manufacturing, materials science, mechanics modelling, sensorics and machine learning. By this, the project will contribute to the development of knowledge-based industry in Norway.