A finite element approach for the prediction of the mechanical behaviour of layered composites produced by Continuous Filament Fabrication (CFF)

Continuous Filament Fabrication (CFF) is the additive manufacturing process for producing material reinforced with long fibres. Differently from other processes, CFF allows producing components in composite materials without using tools, moulds or post-processing operations and with a strengthened area only where it is strictly required. This innovative way of producing composites makes a new design approach necessary for better exploitation of the material. This work presents a preliminary study based on 3D Finite Element (FE) method to predict the mechanical behaviour of composite materials fabricated by CFF. With this aim, a FE model is developed to determine the actual material properties in terms of longitudinal, transverse and shear modulus. Comparisons between experimental and numerical tensile results at different fibre orientations validate the model. The robustness of the proposed approach is confirmed by the comparison with the experimental characterisation of composites produced with two different fibre reinforcements, Carbon and Kevlar®. © 2021 The Author(s)