Control of Continuous Polymer Compounding Fuse Filament Modeling

Controlled processing of carbon microfiber (CMF) reinforced polymers widens control of material properties of fabricated parts. Continuous transfer from compounding to Fused Filament Modeling (FFM) platform brings this advantage to additive manufacturing. CMF reinforced composites are compounded using a co-rotating twin screw extrusion machine (CoTSE). Controlled, direct transfer from the CoTSE to FFM is accomplished using a mechanical system comprised of interconnected feedback control subsystems. Controlled transfer of CMF reinforced composite polymers is studied over a selected range of temperatures, volumetric flow conditions, and microfiber weight fractions using the system. Characteristics of the produced materials are discussed with respect to CMF weight fractions and processing conditions.