Agent-based dual needle additive manufacturing of polymeric filaments in different alignments for manufacturing composites

Additive manufacturing, a rapidly growing production technology in the industrial sector, offers significant advantages for complex geometry production through methods such as fused deposition modeling (FDM). However, polymer parts produced via FDM often exhibit low strength, which limits their practical application. This thesis focuses on improving the mechanical properties of additive manufacturing parts produced using 3D printers. The research investigates diverse strategies to increase the strength of FDM products. A central focus of the thesis is the development of a novel composite material utilizing peroxide as a reinforcement agent and the finding of a regional-based strength-enhancing method during production by cross-linking peroxide and polymer. The 3D printing system enables in-situ composite production, allowing for partial strengthening through agent-based reinforcement while considering stress concentration in the manufactured part. Experimental observations reveal the occurrence of a chemical reaction between the polymer and peroxide materials, resulting in the formation of cross-linking. Additionally, other strategies such as different fiber alignments in pre-production and annealing in post-production were conducted to investigate their impact on the mechanical properties of additive manufacturing products. The findings from both pre-production and post-production interventions demonstrate significant improvements in the mechanical properties of the 3D-printed products.