JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 124

EXPERT'S DIGEST
3D PRINTING

Fig. 2: Image of a
Utah Trikes recumbent
trike frame during
assembly showing
where FDM parts and
fixtures are used

Utah Trikes
Utah Trikes is a specialty recumbent trike
shop based in Payson, Utah. Through the
use of additive manufacturing, they have
built their business on offering customization to the trike market. Utah Trikes utilizes
Stratasys' FDM Nylon 12CF in nearly every
facet of design and manufacturing.
Throughout the product development cycle, the ability to quickly produce functional
prototypes for product testing allows Utah
Trikes to design new products faster.
On the manufacturing floor, the nearly
infinite design freedom coupled with the
high strength, high stiffness, and durability
of FDM materials allows Utah Trikes to
manufacture custom jigs, fixtures, and other
assembly aides to simplify production. Utah
Trikes has even found the FDM Nylon
12CF material to be strong and durable
enough for custom production parts on
their trikes, as depicted in Figure 2. Additive
manufacturing gives Utah Trikes the ability
to customize their products in a whole new
way while simultaneously reducing manufacturing costs and bringing new designs to
market faster.

tions that typically reduce the lead time and
cost associated with traditional composite
tooling.
The US Luge team used Stratasys FDM
technology to produce composite mold
tooling for the entire luge sled. A sacrificial
(washout) tooling material, ST-130, was
used to produce the complex tower geometry that is specially contoured to the athletes
legs and acrylic-styrene-acrylonitrile (ASA)
was used to create a low-temperature layup
tool for the 1.37m sled base. Fabrication
of the tower structure would traditionally
require a complex collapsible core or a cast
washout mandrel, making it cost prohibitive
to manufacture. Additive manufacturing
enables the luge team to create complex athlete-specific sled geometries in a fraction of
the time and at a lower cost than traditional

U.S. Luge Team
The U.S. Olympic Luge Team produces
custom fiberglass sleds for their athletes to
help them compete at the highest levels.
However, composite mold tooling typically
takes weeks or even months to procure and
is often cost prohibitive for low-volume
manufacturing. Additive manufacturing
offers the US Luge Team a range of soluExpert's digest jec

tooling methods.
Summary
The US Luge Team and Utah Trikes are
just two examples where additive manufacturing is impacting the sporting goods
industry. Across nearly all industries; aerospace, defense, automotive and sporting
goods, additive manufacturing is enabling
more efficient design, manufacturing,
and customization. That said, whether for
production parts or tooling applications,
additive manufacturing will not necessarily
replace conventional manufacturing methods, nor is that the intent. In most cases, the
greatest results are achieved by implementing additive manufacturing in a manner that
complements conventional technologies,
combining methods to capitalize on the
strengths of each while avoiding many of
the limitations. As previously indicated, as
athletes evolve so must our manufacturing
processes. Recent advancements in material
capabilities, throughput, and the development of new applications are positioning
FDM as the next evolution in custom
fabrication.
For more case studies, design guides and
general information on FDM tooling, prototyping, and production parts, head over
to the Stratasys website.
More information :
www.stratasys.com

Fig. 3: U.S. Olympic luge team on their
custom composite sled

As published in jec composites
magazine N°118 Jan./Feb. 2018

composites magazine Additive Manufacturing

124


http://www.stratasys.com

JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020

Table of Contents for the Digital Edition of JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020

Contents
Overview - lntroduction to the additive manufacturing of fibre-reinforced composites
Additive manufacturing
Manufacturing  - High-performance creations: additive manufacturing and composites 
Manufacturing - Additive manufacturing of high-performance composite structures 
Technology - Simulating the effects of warpage in an additively-manufactured composite layup tool 
Business insights 
AFP & ATL 
Simulation - Optimizing the key manufacturing parameters of the AFP process 
Simulation - How AFP lay-up affects a composte part’s design intent 
Measurement - Preform permeability measurement and 3D resin flow simulation for dry AFP 
Monitoring - Fibre placement in-process monitoring and solutions for quality optimisation 
Process - Repurposing residual AFP tape for complex aerospace parts 
Process - Rapid manufacturing of a tailored spar by AFP and stamp forming 
Process - PAEK composite prepreg: fast and efficient part manufacturing 
Process - Fibre patch placement: expanding the scope of additive manufacturing 
Process - Automated manufacturing of stiffened composite shells using dry fibre material 
Process - Laser-assisted tape- and fibre-placement-system «Multimaterial Head» 
Process - Economic production of load-optimized thermoplastic composites 
3D printing 
Aerospace - Full-strength 5-axis carbon fibre 3D printing revolutionizes aviation and space 
Aerospace - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing 
Aerospace - lnduction welding of reinforced additive-manufactured parts 
Automotive - The Energica dashboard reinvented through professional 3D printing and composite materials 
Automotive - Transforming composite production processes with FDM additive manufacturing 
Automotive - Disrupting the composite tooling supply chain 
Marine - World’s first 3D-printed yacht with carbon fibre-reinforced thermoplastic compounds  
Sports & Leisure - Additive manaufacturing applications in sporting goods production 
Sports & Leisure - Making the first 3D-printed carbon fibre bike 
Sports & Leisure - lnnovative composite bicycle frame 
Equipment & Machining - Injection moulding: running tests earlier with 3D printing 
Equipment & Machining - Large-scalme additive manufacturing of composite thermoplastics - where are we?
Construction - 3D printing and new materials are the core of China’s smarter cities 
Construction - 3D printing technology for building and construction 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 1
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 3
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Contents
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 5
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Overview - lntroduction to the additive manufacturing of fibre-reinforced composites
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 7
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 8
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 9
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 10
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 11
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 12
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 13
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 14
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Additive manufacturing
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Manufacturing  - High-performance creations: additive manufacturing and composites 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 17
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Manufacturing - Additive manufacturing of high-performance composite structures 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 19
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Technology - Simulating the effects of warpage in an additively-manufactured composite layup tool 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 21
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 22
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Business insights 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 24
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 25
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 26
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 27
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 28
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 29
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 31
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 55
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 56
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 57
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 58
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JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 60
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 61
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 62
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 63
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - AFP & ATL 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Simulation - Optimizing the key manufacturing parameters of the AFP process 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 66
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 67
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Simulation - How AFP lay-up affects a composte part’s design intent 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 69
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 70
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Measurement - Preform permeability measurement and 3D resin flow simulation for dry AFP 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 72
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 73
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 74
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Monitoring - Fibre placement in-process monitoring and solutions for quality optimisation 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 76
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 77
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Repurposing residual AFP tape for complex aerospace parts 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 79
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Rapid manufacturing of a tailored spar by AFP and stamp forming 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 81
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 82
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 83
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - PAEK composite prepreg: fast and efficient part manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 85
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 86
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 87
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Fibre patch placement: expanding the scope of additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 89
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Automated manufacturing of stiffened composite shells using dry fibre material 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 91
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 92
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 93
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Laser-assisted tape- and fibre-placement-system «Multimaterial Head» 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 95
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Process - Economic production of load-optimized thermoplastic composites 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 97
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 98
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 99
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 100
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 101
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 102
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 103
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 3D printing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - Full-strength 5-axis carbon fibre 3D printing revolutionizes aviation and space 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 106
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 107
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - Successful mission of TuPOD, a TubeSats deployer manufactured via additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 109
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 110
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 111
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Aerospace - lnduction welding of reinforced additive-manufactured parts 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 113
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - The Energica dashboard reinvented through professional 3D printing and composite materials 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 115
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - Transforming composite production processes with FDM additive manufacturing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 117
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Automotive - Disrupting the composite tooling supply chain 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 119
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 120
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Marine - World’s first 3D-printed yacht with carbon fibre-reinforced thermoplastic compounds  
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 122
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - Additive manaufacturing applications in sporting goods production 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 124
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - Making the first 3D-printed carbon fibre bike 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 126
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 127
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Sports & Leisure - lnnovative composite bicycle frame 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 129
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Equipment & Machining - Injection moulding: running tests earlier with 3D printing 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 131
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Equipment & Machining - Large-scalme additive manufacturing of composite thermoplastics - where are we?
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 133
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 134
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Construction - 3D printing and new materials are the core of China’s smarter cities 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 136
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 137
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - Construction - 3D printing technology for building and construction 
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 139
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 140
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