Time to think composite: How can you benefit from switching to continuous fiber 3D printing?

It’s no secret that additive manufacturing has been changing and will continue to change our creation and manufacturing processes. In opposition to subtractive manufacturing, objects are conceptualised, designed and then created layer by layer. Such an approach has meant that objects can be optimized: their weight, lead times and cost is considerably reduced. In terms of design, complex shapes can be created, which not only increases their mechanical properties but also saves material. All in all, 3D printing technologies offer benefits that most industries have understood will change the entire manufacturing supply chain. However, limitations to this process still exist. One of the main limitations relates to the availability of materials. There are plastics, there are metals, but is that it?

An aircraft seat support piece has been optimized thanks to topology optimization

Plastic or Metal – is there more?

A company that wishes to take on additive manufacturing is faced with two choices: plastic or metal. However, both have their limitations. Plastic 3D printing is typical for prototyping, it’s easy, cheap, and many companies are familiar with the technology. In most cases, end-use parts that require higher mechanical properties are made out of metal. Machines and materials for metal 3D printing are expensive and the process is not so easy itself.

Are composites the solution?

Composite materials can produce functional, load-bearing parts that are easy to produce and affordable at the same time. When people hear about composites, they imagine polymers filled with short/chopped fibers. These are indeed composites too but they will not solve the issues mentioned above. In fact, composites with short fibers are about 2 times stronger than plastic so they shouldn’t be used for end-use parts. However, composites reinforced with continuous fibers are up to 20 times stronger than pure plastic and comparable or even stronger than metals. They are also several times lighter and cheaper than the latter.