Carbon / CFK – faserverstärkte Kunststoffe für Ersatzteile aus dem 3D-Drucker

The development of 3D printing continues to advance and the industry can no longer be imagined without it. In addition to traditional materials such as steel and aluminium, it is now even possible to produce components from carbon fibre-reinforced plastic (aka carbon) with the help of additive manufacturing. By combining the advantages of 3D printing with those of the high-strength material, extremely stable components with a very good surface finish can be produced without great effort.

What exactly is carbon fibre reinforced plastic (CFRP)??

It is a composite material in which carbon fibres are embedded in several layers in a plastic matrix for reinforcement. This ensures that the subsequent components have extreme strength and rigidity.

Carbon fibre filaments are used in 3D printing. These are conventional 3D printing filaments made of carbon fibre reinforced plastic. As a rule, cut carbon fibres that are less than one millimetre long are added to the typical thermoplastic. Continuous fibre strands can also be used, which are significantly stronger but require a more complex printing process. The most commonly used carbon fibre filaments are PET-CF and HI-TEMP CF.

Why choose carbon fibre filament?

• Extreme strength
• Low weight
• Temperature resistance
• Stiffness

The filaments reinforced with carbon fibres have the advantage that they only have a very low mass despite their high strength. In addition, they can withstand significantly higher temperatures compared to conventional filaments. PET-CF, for example, is resistant up to 100 °C. Furthermore, components manufactured with carbon fibre 3D printing retain their shape even under high loads.

However, the following points should be noted:

• Higher material costs
• Special equipment necessary
• Low impact resistance

Since the cost of producing carbon fibre filament is higher than that of PLA, for example, the price is correspondingly higher. When printing components made of CFRP, the wear of the nozzle is significantly higher than with other filaments, which is why a nozzle made of hardened steel must inevitably be used. In addition, a heated print bed and a higher printing temperature are necessary. Furthermore, the carbon filament also brings with it a negative material property, as fractures can occur in the material in applications with high impact force.

Reconstruction of vehicle parts from CFRP

Due to the good surface quality and the enormous stability of the components, carbon 3D printing offers many possible applications. In addition to toolmaking and aerospace technology, it is also ideal for the reconstruction of vehicle parts.

The underbody protection of a BMW E24 635 CSi shown here was reproduced with carbon fibre filament using the additive FDM manufacturing process. The material used is HI-TEMP CF, a high-strength carbon fibre-reinforced filament that remains stable at temperatures of up to 115 °C.

However, the advantages of additive manufacturing, in the production of components made of CFRP, cannot only be used for direct printing. Rather, 3D printing can be used to create even complex and large moulds for the subsequent components in a very short time and without much effort. The carbon fibre mats, pre-impregnated with epoxy resin, are then inserted into the moulds and cured in a vacuum bag under the influence of appropriate temperature and pressure.

Conclusion

Taking into account the factors mentioned above, very light and at the same time high-strength components can be produced with the help of carbon fibre 3D printing, which are used in many areas. The components made of CFRP are very durable and are hardly inferior to products made of conventional materials. You want to know the price for your spare part? Send us an enquiry!rage!