A Design Methodology for Continuous Fiber Additive Manufacturing Using Advanced Computer Aided Engineering Technique

A design methodology for Continuous Carbon Fiber Additive Manufacturing (CCFAM) developed using Computer Aided Engineering (CAE) techniques takes advantage of both the mechanical strength of composite materials and the Fused Filament Fabrication (FFF) method. By performing topology optimization and Finite Element Analysis (FEA) on a load-bearing part, engineers can design much lighter optimized parts that are just as strong as those produced using FFF. This weight reduction is achieved by relying on the mechanical strength of continuous carbon fibers printed alongside a traditional thermoplastic matrix. The FFF additive manufacturing method enables the production of complex shapes, which can match the load-driven, organic geometries derived from topology optimization and other advanced CAE techniques. The efficacy of this design methodology has been demonstrated in a design case study of a motor mount for a vertical take-off and landing drone.