Abstract
Additive manufacturing technologies are among the most flexible and easily reconfigurable processes available in the field of polymers and reinforced polymers. Unfortunately, the common materials are, at the best, polymers reinforced with short fibers, with properties far from those of conventional “structural” materials like steels and aluminum alloys. A very recent approach, however, allows the deposition of filaments reinforced with continuous fibers. In the ASCENT project this approach is identified as Continuous Fiber Fused Filament Fabrication (CF4). When carbon fibers are used as a reinforcement, CF4 can provide structural products with overall properties comparable if not superior to those of products manufactured with conventional technologies and materials, also with the great advantage of a very high degree of reconfigurability, highly demanded in this period of rapid changes and instability of the industrial trajectories (also enhanced by the pandemic crisis). A further great and unique advantage comes from the potential implementation of CF4 in combination with topological optimization strategies leading to the manufacturing solutions of structural parts with unique and unrivalled geometries and performances. The typical application of thermoplastic matrices for additive CF4 processes also orient the manufacturing towards products with a high degree of recyclability, a fundamental feature in view of a greener and circular economy. Despite the huge potentialities, this is a very recent technology, and its full exploitation still requires several issues to be tackled: 1) There is currently a lack of knowledge on the process parameters-morphology-structural performance correlation, mainly under cyclic loadings. 2) The scientific literature is completely lacking models and methods for the safe and efficient design of structural CF4 parts. 3) Topological optimisation methodologies, integrated with the models above, are of crucial importance to fully exploit the flexibility offered by this technology. In view of these observations, the project has the following objectives: 1) Increasing the knowledge on the influence of the CF4 process parameters and constituents on the material morphology and mechanical performances, mainly at long term, allowing the identification of optimal process conditions. 2) Developing and implementing models for predicting the static and fatigue structural performances of parts obtained through the CF4 process. 3) Development of topological optimisation strategies, combined with the previously defined models, for the optimal and efficient design. Reaching these targets would lead to an unrivalled increase in the knowledge on the CF4 process and in the properties of the manufactured components. In addition, these results, together with a careful dissemination activity, will shed light onto the advantages of this technology, increase its attractivity and promote its use in several industrial sectors. RESULTS ACHIEVED The ASCENT project has clearly demonstrated the transformative potential of Continuous Fiber Fused Filament Fabrication (CF4) for the production of high-performance structural components. By addressing critical gaps in knowledge related to process–structure–property relationships, structural design, and optimization methodologies, the project has laid a robust foundation for the safe, efficient, and widespread adoption of this emerging technology. A key strength of the project lies in the integrated approach combining experimental investigations, advanced modeling, and optimization strategies. The systematic analysis of process parameters and their influence on material morphology and mechanical behavior has enabled the definition of optimized manufacturing conditions, ensuring improved quality and repeatability of printed components. In parallel, the development of predictive models for elastic response, strength, and fatigue life—together with their implementation into computational tools—represents a significant advancement toward reliable and performance-driven design of CF4 structures. Furthermore, the development of topology optimization methodologies specifically tailored to CF4 has highlighted the unique design freedom offered by this technology. The ability to simultaneously optimize geometry and fiber trajectories opens new possibilities for lightweight, high-efficiency structures that are not achievable with conventional manufacturing processes. Combined with the use of thermoplastic matrices, this also supports increased recyclability and aligns with the growing demand for sustainable and circular manufacturing solutions. In conclusion, the project objectives have been fulfilled. The results of the ASCENT project represent a significant step forward in the field of additive manufacturing of continuous fiber-reinforced composites. The knowledge, models, and methodologies developed within the project provide essential tools for both researchers and industry, paving the way for the broader implementation of CF4 in advanced structural applications. A wide dissemination on journals, conferences and exhibitions allowed the spreading of results among the scientific but also industrial communities.
Dettagli del progetto
Responsabile scientifico: Edoardo Ida
Strutture Unibo coinvolte:
Dipartimento di Ingegneria Industriale
Coordinatore:
Università degli Studi di PADOVA(Italy)
Contributo totale Unibo: Euro (EUR) 92.229,00
Durata del progetto in mesi: 24
Data di inizio
28/09/2023
Data di fine:
28/02/2026
