Methodology to design and optimise dispersed continuous carbon fibre composites parts by fused filament fabrication

Dispersed continuous carbon fibre laminates improve specific capabilities of composites under predefined load conditions. The 3D printing technology based on Fused Filament Fabrication (FFF) allows for the exact setup of the continuous reinforcement orientation. This article proposes a novel methodology to design, manufacture and optimise structural parts with mechanical behaviour adapted to applications. The new methodology encompasses: (i) customised mechanical properties, (ii) manufacturing via 3D printing and post-processing, (iii) characterisation of advanced material models for finite element simulations, and (iv) virtual testing of the structural part considering the 3D printer limitations. An aluminium motorcycle triple tree has been replaced with an optimised 3D printed composite part for braking and cornering. The mechanical properties of the 3D printer laminates have been enhanced via pressurised post-processing at 150 °C for 15 min. The good agreement between coupon experiments and simulations validates the advanced material models used in the virtual tests. •Methodology to optimise 3D printed dispersed laminates under printer limits.•Experimental and numerical characterisation of 3D printed dispersed CFRP.•Thermal post-process reduces porosity and increase properties keeping dimensions.•FE models reproduces experimental behaviour before and after post-process.