Impact and tensile performance of continuous 3D-printed Kevlar fiber-reinforced composites manufactured by fused deposition modelling

The current study evaluated the mechanical characteristics of continuous Kevlar fiber-reinforced composite (KFRCP), which were 3D-printed using fused filament fabrication. Markforged MarkTwo 3D printer was used to fabricate KFRCP. The matrix material used was onyx, and the reinforcing material was continuous Kevlar fiber. Mechanical characteristics were evaluated using tensile and impact tests. The influence of changing fiber orientation, fiber direction, and reinforcement on mechanical properties was also investigated. Mechanical properties of KFRCP with reinforcement and virgin onyx (without reinforcement) were compared. When compared to virgin onyx, the tensile strength of KFRCP rose up to 11 times, while the impact strength increased up to three times. The experimental result showed that fiber mechanical properties are dependent on the direction of loading of the fiber. The directional dependent properties of Kevlar fiber reveal its anisotropic property. The result showed that the mechanical properties of KFRCP improved with increase in reinforcement. Additionally, it was observed that as reinforcement levels increased, the matrix loses its ability to perforate the fiber. If the matrix is unable to perforate the fiber, delamination is a significant problem. From a design perspective, the ultimate tensile strength and impact strength of any material are essential. The data produced will serve as the blueprint for structural modelling and cost analysis for design engineers.