Bonding between additively manufactured parts and CFRP: An investigation to increase mechanical performance by acting on joint geometry
Matteo Benvenuto, Marco Pizzorni, Chiara Mandolfino, Luigi Benvenuto, Enrico Lertora
Abstract. In recent years, 3D printing with polymeric materials has emerged as one of the most relevant innovations in the industrial field, especially in those sectors where reducing of production time is crucial. This technology, based on progressive material deposition, has revolutionised the industry, though certain challenges remain to be addressed. These include the mechanical performance of printed parts that is not always optimal, a problem addressed by the insertion of reinforcements, both short and continuous. Another significant challenge relates to the feasibility of assembling multiple parts to create objects larger than the printing volumes of the machines. Currently, among the various techniques that can be used to connect the components, bonding is generally chosen. In this way, it is possible to assemble the various elements by inserting, when necessary, reinforcing parts in different materials (such as metal or CFRP). Great attention must be paid to the bonding area in this case, as this is often the area where structural failure occurs. This can be due to various causes, such as sub-optimal working conditions of the adhesive, poor adhesion properties to the substrate and ineffective surface preparation of the adherends. Based on these premises, this experimental work explores the aspects inherent to the design, fabrication, and mechanical characteristics of heterogeneous bonded joints between CFRP substrates and additively manufactured composite substrates (Onyx™). In particular, geometric solutions of the joints are proposed to improve the working conditions of the adhesive (Permabond® TA4660). The analysis was conducted by subjecting all the joints to a shear strength test according to ASTM D3163 and analyzing the fracture surface of the specimens.
Keywords
Adhesive Bonding, Composites, 3D Printing
Published online 5/7/2025, 10 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Matteo Benvenuto, Marco Pizzorni, Chiara Mandolfino, Luigi Benvenuto, Enrico Lertora, Bonding between additively manufactured parts and CFRP: An investigation to increase mechanical performance by acting on joint geometry, Materials Research Proceedings, Vol. 54, pp 189-198, 2025
DOI: https://doi.org/10.21741/9781644903599-21
The article was published as article 21 of the book Material Forming
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
References
[1] U. M. Dilberoglu, B. Gharehpapagh, U. Yaman, and M. Dolen, “The Role of Additive Manufacturing in the Era of Industry 4.0,” in Procedia Manufacturing, 2017. https://doi.org/10.1016/j.promfg.2017.07.148
[2] A. Jandyal, I. Chaturvedi, I. Wazir, A. Raina, and M. I. Ul Haq, “3D printing – A review of processes, materials and applications in industry 4.0,” Sustainable Operations and Computers, vol. 3, 2022. https://doi.org/10.1016/j.susoc.2021.09.004
[3] G. Prashar, H. Vasudev, and D. Bhuddhi, “Additive manufacturing: expanding 3D printing horizon in industry 4.0,” International Journal on Interactive Design and Manufacturing, vol. 17, no. 5, 2023. https://doi.org/10.1007/s12008-022-00956-4
[4] M. Ramadany and M. S. Bajjou, “Applicability and integration of concrete additive manufacturing in construction industry: A case study,” Proc Inst Mech Eng B J Eng Manuf, vol. 235, no. 8, 2021. https://doi.org/10.1177/0954405420986102
[5] X. Yan and P. Gu, “A review of rapid prototyping technologies and systems,” Computer-Aided Design, vol. 28, no. 4, pp. 307–318, Apr. 1996. https://doi.org/10.1016/0010-4485(95)00035-6
[6] T. Rayna and L. Striukova, “From rapid prototyping to home fabrication: How 3D printing is changing business model innovation,” Technol Forecast Soc Change, vol. 102, pp. 214–224, Jan. 2016. https://doi.org/10.1016/j.techfore.2015.07.023
[7] S. C. Ligon, R. Liska, J. Stampfl, M. Gurr, and R. Mülhaupt, “Polymers for 3D Printing and Customized Additive Manufacturing,” 2017. https://doi.org/10.1021/acs.chemrev.7b00074
[8] A. Villa, P. K. Gianchandani, and F. Baino, “Sustainable Approaches for the Additive Manufacturing of Ceramic Materials,” 2024. https://doi.org/10.3390/ceramics7010019
[9] N. D. Dejene and H. G. Lemu, “Current Status and Challenges of Powder Bed Fusion-Based Metal Additive Manufacturing: Literature Review,” 2023. https://doi.org/10.3390/met13020424
[10] J. Huang, Q. Qin, and J. Wang, “A Review of Stereolithography: Processes and Systems,” Processes, vol. 8, no. 9, p. 1138, Sep. 2020. https://doi.org/10.3390/pr8091138
[11] S. Khan, K. Joshi, and S. Deshmukh, “A comprehensive review on effect of printing parameters on mechanical properties of FDM printed parts,” in Materials Today: Proceedings, 2021. https://doi.org/10.1016/j.matpr.2021.09.433
[12] S. Wickramasinghe, T. Do, and P. Tran, “FDM-Based 3D printing of polymer and associated composite: A review on mechanical properties, defects and treatments,” 2020. https://doi.org/10.3390/polym12071529
[13] K. I. Ismail, T. C. Yap, and R. Ahmed, “3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques,” 2022. https://doi.org/10.3390/polym14214659
[14] J. F. Liu, Y. G. Zhou, S. J. Chen, S. Q. Ren, and J. Zou, “Effects of Friction Stir Welding on the Mechanical Behaviors of Extrusion-Based Additive Manufactured Polymer Parts,” Polymers (Basel), vol. 15, no. 15, 2023. https://doi.org/10.3390/polym15153288
[15] W. Lv, X. Qin, Z. Bao, W. Guo, X. Meng, and H. Li, “Comparison of joining hole making methods for fiber reinforced FDM 3D printing parts,” Proc Inst Mech Eng B J Eng Manuf, 2024. https://doi.org/10.1177/09544054231223265
[16] J. L. Amaya, E. A. Ramírez, F. Maldonado Galarza, and J. Hurel, “Detailed design process and assembly considerations for snap-fit joints using additive manufacturing,” in Procedia CIRP, 2019. https://doi.org/10.1016/j.procir.2019.04.271
[17] A. G. Magalhães, M. F. S. F. De Moura, and J. P. M. Gonçalves, “Evaluation of stress concentration effects in single-lap bonded joints of laminate composite materials,” Int J Adhes Adhes, vol. 25, no. 4, 2005. https://doi.org/10.1016/j.ijadhadh.2004.10.002
[18] S. M. F. Kabir, K. Mathur, and A. F. M. Seyam, “The Road to Improved Fiber-Reinforced 3D Printing Technology,” Technologies (Basel), vol. 8, no. 4, 2020. https://doi.org/10.3390/technologies8040051
[19] ASTM INTERNATIONAL, “ASTM D 3163-01 Standard Test Method for Determining Strength of Adhesively Bonded Rigid Plastic Lap-Shear Joints in Shear by Tension Loading,” ASTM Book of Standards, vol. 01, no. Reapproved 008, 2023.
[20] “Markforged Inc. Material Specification.” Accessed: Mar. 20, 2024. [Online]. Available: https://s3.amazonaws.com/mf.product.doc.images/Datasheets/Translations/IT/Markforged_CompositesV5.1_it.pdf
[21] “PERMABOND® TA4660 – Technical Datasheet.” Accessed: May 17, 2024. [Online]. Available: https://www.permabond.com/wp-content/uploads/2022/10/TA4660_TDS.pdf
