Finite Element Analysis of Additively Manufactured Continuous Carbon Fiber-Reinforced Composites

The objective of this study is to provide a numerical modeling approach for continuous carbon fiber (CCF)-reinforced fused filament fabricated composites. Although these materials have been extensively studied, an effective numerical modeling technique for their mechanical performance does not exist. To fill this technical gap, a numerical modeling approach based on finite element analysis is presented. The effective material properties of the Onyx matrix when voids are present are derived by the Kerner model. The material properties of CCF-reinforced composites are modeled by Hashin’s model. Both the flexural and tensile properties are simulated. The modeling approach is validated against various experimental results.