Evaluation of recycled carbon fibers as PLA reinforcement for additive manufacturing applications

The increased exploitation of carbon fiber reinforced polymers (CFRP) is inevitably bringing about an increase in production scraps and end-of-life components, resulting in a sharp increase in CFRP waste. Therefore, it is of paramount importance to find efficient ways to reintroduce waste into the manufacturing cycle. At present, several recycling methods for treating CFRPs are available, even if all of them still have to be optimized. The step after CFRP recycling, and also the key to build a solid and sustainable CFRP recycling market, is represented by the utilization of Re-CFs. The smartest way to utilize recovered carbon fibers is through the manufacturing of recycled CFRPs, that can be done by re-impregnating the recovered fibers with a new polymeric matrix. Fused Filament Fabrication (FFF) is one of the most widely used additive manufacturing (3D printing) techniques that fabricates parts with a polymeric filament deposition process that allows to produce parts adding material layer-by-layer, only where it is needed, saving energy, raw material cost, and waste. The filament can also contain fillers or reinforcements such as recycled short carbon fibers and this makes it perfectly compliant with the re-application of the shortened recycled CF. Therefore, in this thesis work recycled and virgin carbon fiber reinforced PLA filaments have been initially produced using 5% and 10% of CFs load. Properties and characteristics of the filaments have been determined conducting different analysis (TGA, DMA, DSC). Subsequently the 5%wt. Re-CFs filament has been used to 3D print specimens for mechanical characterization (DMA, tensile test and CTE), in order to evaluate properties of printed PLA composites containing Re-CFs and evaluate the feasibility of Re-CFs in 3D printing application