Session: 03-02-01: Advanced Manufacturing

Paper Number: 151334

151334 - Sustainable Aerospace Composites: Enhancing Mechanical Performance of FFF-Printed Onyx Through Fibre Optimization 

Carbon fiber composites, known for their high strength-to-weight ratio, have been widely adopted in the construction of critical components such as aircraft fuselages, wings, and structural reinforcements. However, traditional composite manufacturing methods, while effective, are time-consuming, costly, and resource-intensive. Fused Filament Fabrication (FFF), a form of additive manufacturing, offers a sustainable alternative by producing complex geometries with minimal waste. However, FFF-printed parts, especially those made from standard thermoplastics, often lack the mechanical robustness required for high-stress aerospace applications.

To address this issue, this study explores the mechanical performance of nylon-carbon (Onyx) composites and carbon fiber-reinforced Onyx composites by modifying their orientation. Two different orientations ([0,90]s and [0,45,90,-45]s) were evaluated and compared with unoriented composites. It was noted that the oriented composites exhibited higher strength—approximately 45% and 25% improvements in flexural and tensile strength, respectively. Failure analysis using scanning electron microscopy revealed that fiber orientation delayed crack propagation, enhancing overall durability, with fiber pull-out acting as a major failure mechanism.

These results demonstrate that fiber alignment during the FFF process can significantly improve the mechanical properties of composites. The findings provide a viable pathway for expanding the use of FFF-printed composites in high-performance applications, particularly in the aerospace and automotive industries where sustainability and mechanical efficiency are critical. This study highlights the potential of FFF and offers practical design strategies to enhance the mechanical capabilities of additively manufactured composites.

Presenting Author: Constance Gnanasagaran Kingston University London

Presenting Author Biography: Constance Gnanasagaran is a Chartered Engineer and Senior Lecturer in Mechanical Engineering at Kingston University’s Roehampton Vale campus. Since joining Kingston in September 2021, she has been instrumental in shaping the academic experience as the Course Director for the MSc in Advanced Product Design Engineering and Manufacturing. Constance brings a diverse and international perspective to her role, having spent over seven years teaching Mechanical Engineering at prestigious universities in Malaysia before moving to the UK.

Constance’s academic career is driven by her passion for ensuring that engineering graduates are well-prepared for the challenges of the modern industry. She is dedicated to enhancing the curriculum to meet evolving industry standards and building strong relationships with students and collaborators alike.

Her research interests are primarily focused on Tissue Engineering and Regenerative Medicine, with a particular emphasis on Bone Tissue Engineering. Her work spans various subfields, including Additive Manufacturing, Bioprinting, Vascularization Studies, and Wound Healing Stimulations. Additionally, Constance is actively involved in research on Advanced Materials and Additive Manufacturing for Aerospace Applications, particularly in extreme environments, contributing to innovation in high-performance materials for challenging aerospace conditions.

In addition to her academic and research endeavors, Constance serves on the board of the Biomedical Division of the IMechE UK, collaborating with fellow engineers to foster innovation in the field. She is also a dedicated mentor within the Women in Engineering Society (UK), where she strives to inspire and support the next generation of female engineers.

Driven by a deep commitment to learning, innovation, and mentorship, Constance is making significant contributions to both engineering education and research, with a particular focus on advancing the fields of tissue engineering, regenerative medicine, and aerospace materials.