Effect of moisture content on the mechanical performance of 3D printed continuous reinforced two-matrix composite

Additive manufacturing, particularly Fused Filament Fabrication, has gained significant attraction in recent years. In order to increase the mechanical performances of several components, continuous reinforcements, such as carbon fibers, can be coextruded with a polymeric matrix.The present study relies on a specific 3D printing process, called towpreg coextrusion, which exploits continuous carbon fibers covered with an epoxy resin and polyamide (PA) as the thermoplastic matrix, thus obtaining a 3D printed two-matrix composite. Since polyamide is a highly hygroscopic material, the impact of moisture content on the mechanical properties of 3D-printed continuous composites was investigated. Tensile and flexural specimens were manufactured and tested under both undried and dried conditions. Drying treatment was carried out at a temperature of 70 degrees C for 2 h in oven, with weight measurements before and after for quantifying weight loss and then the moisture removal. Additionally, through thermogravimetric analysis, the thermal stability of the material was assessed. It was observed that the drying process allows for a reduction of up to 0.56% by weight of moisture in the specimens. Thus, the drying process led to an improvement in the mechanical properties of the material. Specifically, the tests reveal a 15% increase in tensile strength and an 11.5% increase in flexural strength following the drying process, reaching values of 392.78 MPa and 151.06 MPa, respectively. Similarly, an increase in the tensile and flexural moduli was noted in the treated specimens. Finally, fractured samples underwent optical and scanning electron microscopy analysis, through which different fracture mechanisms of the material and the presence of macrovoids and microvoids attributable to the 3D printing process were observed. Knowledge of deposition defects represents an important starting point for the improvement of the process and the mechanical properties obtained to date. This research provides valuable insights into optimizing 3D-printed continuous composites, emphasizing the importance of moisture control for superior mechanical performance in industrial applications.