JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 8

EXPERT'S DIGEST
ADDITIVE MANUFACTURING
Tab.4: Fibre-reinforced composites additive manufacturing Process Categories according to ISO/ASTM
52900:2015(en)				
Source : Connectra Research

Filament
Winding

Process Category

Automated Fiber Placement Other Composites Additive
(AFP) Automated Tape
Manufacturing
Laying (ATL)
processes including 3D
printing

Binder jetting
Directed energy deposition

X

X

Material extrusion

X

Material jetting
Powder bed fusion

X

Sheet lamination

X

X

Vat photopolymerization

X

Uncategorised

X

three categories of composites additive
manufacturing fit with the ISO/ASTM
categories. Note that the ISO/ASTM categories do not seem to have a place where
filament winding naturally fits.
These fibre reinforced composites additive
manufacturing processes will be reviewed
in more depth in later sections of this
introduction.
Scope of composite reinforcement fibres
and matrices used in AM
As mentioned above, the key triad of fibre-reinforced composites manufacturing
includes the process, the raw materials
and software. The basic raw materials
used are reinforcement fibres and matrices
of various kinds. Table 5 gives the most
commonly used types of fibres in fibre-reinforced composites, either directly or in
intermediate form of either a prepreg or

preform.
Generally, in fibre-reinforced composites,
glass fibre is by far the largest volume of reinforcement used but in additive manufacturing carbon fibre and some of the other
fibres mentioned are more commonly
used as they offer superior properties to
glass, which are often desirable for the
type of parts being produced.
Similarly, a wide variety of matrices are
used in the additive manufacture of fibre
reinforced composites and these are summarised in Table 6. It should be noted that

Tab.6: Specific matrices most commonly used in the additive manufacture of fibre-reinforced composite
applications

Matrix Type

Specific matrix

Thermoset
polymer matrix

Unsaturated Polyester Resin (UPR)
Vinyl Ester Resin (VER)
Epoxy Resin (EP)
Acrylic Resin
Phenolic Resin

Tab.5: Specific reinforcement fibres most
commonly used in the additive manufacture of
fibre-reinforced composite applications

Fibre type

Specific fibre

Inorganic

Glass fibre:
specifically, as E, E-CR (Corrosion
Resistant) glass fibre and A-R
(Alkali Resistant) glass fibre
Basalt fibre

Organic
Metallic

the broadest possible scope of the word
composites has been used, including both
gypsum and concrete which are used in
3D printing.
The big challenge for any fibre-reinforced
composite process is to make optimum
use of the reinforcement properties of any
particular fibre in any particular matrix.
The strength properties of the composite
part will very much depend on multiple
factors related to the fibre, namely:
fibre type, fibre length, fibre orientation,
strength of the bond between the matrix
and the fibre surface (which can be heavily
influenced by a sizing that is applied to the
fibre to enhance that bonding).
Most of the developments in the newer
additive manufacturing processes for
fibre-reinforced composites have come
about in the search for solutions to the
issues of optimum fibre length and fibre
orientation. This will be discussed in more
detail in the specific technology sections.
It should also be noted that to ease the
fabrication of the finished part from the
raw materials, a premix of fibre and matrix,
usually referred to as a prepreg, is often
used. For instance, automated tape laying
can use unidirectional tapes made up of
carbon fibres either in a semi-cured thermoset resin or impregnated by a thermoplastic. The same pre-impregnation can

Carbon fibre
Aramid fibre
Polyethylene fibre

Thermoplastic
polymer matrix

Inorganic matrix
(non-polymer)

Steel fibre

Expert's digest jec

Polyamide (PA)
Polypropylene (PP)
Polylactic Acid (PLA)
Polycarbonate (PC)
Acrylonitrile Butadiene Styrene (ABS)
Polyphenylene Oxide (PPO)
Polyetherimide (PEI)
Polyether ether ketone (PEEK)
Polysulfone (PSU)
Polyphenylene Sulphide (PPS)
Gypsum
Concrete
Ceramic
Metal

composites magazine Additive Manufacturing

8



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 - 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
JEC COMPOSITES MAGAZINE - EXPERT’S DIGEST - ADDITIVE MANUFACTURING - 2020 - 59
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
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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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https://www.nxtbook.fr/newpress/jeccomposites/jcm-experts-digest-additive-manufacturing-2020
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https://www.nxtbook.fr/newpress/jeccomposites/jcm2009_136
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