Direct deposition of CF/PEKK composite shims on CF composite laminates for aeronautics
Giorgio PATRIZII, Denise BELLISARIO, Dounia NOQRA, Leandro IORIO, Alice PROIETTI, Fabrizio QUADRINI, Loredana SANTO
Abstract. A new deposition system, composed by a 4-axis robot (Epson SCARA T3-401S), an extrusion head (E3D Titan Aero Kit), a bench power supply and a controller (Duet 2 WiFi), was prototyped for layer-additive-manufacturing (LAM) of carbon fiber (CF) poly-ether-ketone-ketone (PEKK) composites. The extrusion device has been modified to allow the deposition of tapes instead of circular filaments used in fused deposition modeling (FDM), that represents the conventional technology for this kind of application. An elastic connection, composed by 4 springs, was placed between the robot end-effector and the extruder to guarantee tape agglomeration during manufacturing. Deposition tests of 20 layers of CF-PEKK thermoplastic composite were carried on a CF-epoxy laminate as substrate, at the extrusion temperature of 420°C and the rate of 60 mm/min. Adhesion was high even if the substrate had a thermoset epoxy matrix. The CF-PEKK composite showed a good surface appearance, irregularities and misalignments were not visible at the end of manufacturing process. Good adhesion of the 3D printed part is fundamental to evaluate the feasibility of the prototyped LAM machine to deposit aeronautic shims. Machining tests have shown that the deposited CF-PEKK composite is well bonded to the surface of the traditional CF-epoxy laminate. In fact, even with the small size of the deposited part, the CF-PEKK composite has been machined without any issue.
Keywords
Additive Manufacturing, Shape Memory Polymer Composites, Smart Hinges, Space
Published online 5/7/2025, 9 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Giorgio PATRIZII, Denise BELLISARIO, Dounia NOQRA, Leandro IORIO, Alice PROIETTI, Fabrizio QUADRINI, Loredana SANTO, Direct deposition of CF/PEKK composite shims on CF composite laminates for aeronautics, Materials Research Proceedings, Vol. 54, pp 2093-2101, 2025
DOI: https://doi.org/10.21741/9781644903599-225
The article was published as article 225 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.
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