Sample preparation and image acquisition using optical-reflective microscopy in the measurement of fiber orientation in thermoplastic composites

Summary A complete sample preparation procedure used to determine three‐dimensional fiber orientation from optical micrographs of glass fiber‐reinforced thermoplastic composites is presented. Considerations for elimination of irregularities in the elliptical footprints, contrast enhancement between fibers and surrounding polymer matrix, controlled‐etching that allows the identification of small shadows where fiber recedes into the matrix, and topographical reconstruction of the elliptical footprint are described in the procedure. This procedure has produced high‐quality optical micrographs employed to obtain accurate fiber orientation data for thermoplastic composites using the method of ellipses. The optimal definition of the nonelliptical footprints’ borders allows an accurate measurement of orientation in small sampling areas.