Carbon fiber-reinforced composites (CFRPs) are gaining prominence in automobile and aeronautical sectors, attributable to their exceptional specific weight, lightweight nature, and durability. Howbeit, the escalating adoption of CFRPs has concurrently led to a substantial increase in waste, derived from obsolete pre-pregs, manufacturing offcuts, end-of-life components, and production tooling. This surge in waste-generation presents significant environmental challenges, underscoring the imperative for advanced recycling methodologies to sustain environmental stewardship and foster circular-economy. In this context, the present research investigates the potential of 3D-printing as a sustainable and economically viable approach for reusing waste carbon fiber fabric into high-value products. This study leverages the synergistic integration of two distinct additive manufacturing (AM) techniques, DIW (Direct Ink Writing) and FDM (Fused Deposition Modeling), to fabricate sandwich structures combining nylon and waste carbon fiber as core. The research highlights the mechanical performance of fabricated composites, demonstrating augmentation in properties compared to pristine nylon. The mechanical testing revealed that tensile strength of nylon carbon fiber-reinforced composite exhibited a notable increase, reaching 86.36 MPa, a substantial improvement from 54.7 MPa observed in unreinforced nylon. Furthermore, impact strength of composite exhibited a dramatic surge, escalating from 56.8 to 420.565 J/m2. These findings underscore the potential of this recycling approach not only to transform industrial waste into valuable resources and mitigate environmental impact but also to produce high-performance composites suitable for demanding applications in automobile and aeronautical sectors.

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Recycling Carbon Fiber via Additive Manufacturing for Superior Mechanical Properties

  • Sanket Dilip Meshram,
  • Shruti Gupta,
  • Jigar Patadiya,
  • Balasubramanian Kandasubramanian

摘要

Carbon fiber-reinforced composites (CFRPs) are gaining prominence in automobile and aeronautical sectors, attributable to their exceptional specific weight, lightweight nature, and durability. Howbeit, the escalating adoption of CFRPs has concurrently led to a substantial increase in waste, derived from obsolete pre-pregs, manufacturing offcuts, end-of-life components, and production tooling. This surge in waste-generation presents significant environmental challenges, underscoring the imperative for advanced recycling methodologies to sustain environmental stewardship and foster circular-economy. In this context, the present research investigates the potential of 3D-printing as a sustainable and economically viable approach for reusing waste carbon fiber fabric into high-value products. This study leverages the synergistic integration of two distinct additive manufacturing (AM) techniques, DIW (Direct Ink Writing) and FDM (Fused Deposition Modeling), to fabricate sandwich structures combining nylon and waste carbon fiber as core. The research highlights the mechanical performance of fabricated composites, demonstrating augmentation in properties compared to pristine nylon. The mechanical testing revealed that tensile strength of nylon carbon fiber-reinforced composite exhibited a notable increase, reaching 86.36 MPa, a substantial improvement from 54.7 MPa observed in unreinforced nylon. Furthermore, impact strength of composite exhibited a dramatic surge, escalating from 56.8 to 420.565 J/m2. These findings underscore the potential of this recycling approach not only to transform industrial waste into valuable resources and mitigate environmental impact but also to produce high-performance composites suitable for demanding applications in automobile and aeronautical sectors.