Fundamental Study of Press Molding Method for CFRP Preform Using a 3D Printer

Carbon fiber reinforced plastic (CFRP) is a composite material with high specific strength and is applied to transportation and aviation equipment. However, conventional processing methods require large-scale production apparatus or a high level of dexterity that only comes with extensive experience which makes it difficult to achieve high processing efficiency. The objective of this study is to develop a novel method for forming thermos-plastic CFRP (CFRTP) preforms implementing a 3D printer for press molding. Applying this method offers the advantage that continuous carbon fibers can be formed on a free-form surface. It also reduces the manufacturing time and operator skill required. The goal of this research is to establish a method for molding a free-form surface composed of continuous fibers by employing a 3D-printed preform designed to match the unfolded polygonised diagram of the free-form surface. Previous research introduced an unfolding approach for converting a three-dimensional shape to a plane surface based on a computer-aided design and manufacturing (CAD/CAM) system, enabling the generation of an unfolding diagram that maintains the continuity of fiber tow. Furthermore, the validity of unfolded diagram was confirmed by reproducing the objective three-dimensional shape from the unfolded diagram using thermos-setting CPRP (CFRTS) tow prepreg. In this study, the viability of the proposed molding process using CFRTP preform fabricated by a 3D printer was verified and an assessment of the formability of the molded parts was conducted.