Optimizing processing conditions for additively reinforced thermoforming (ART) in convergent manufacturing

Talabi, Segun Isaac; Smith, Tyler; Rodriguez, Brittany; Ogle, Ryan; Elyas, Sana; Nuttall, David; Kunc, Vlastimil; Kumar, Vipin; Hassen, Ahmed Arabi

doi:10.1016/j.mtcomm.2025.112870

Optimizing processing conditions for additively reinforced thermoforming (ART) in convergent manufacturing

Journal Article · Tue May 20 04:00:00 EDT 2025 · Materials Today Communications

DOI:https://doi.org/10.1016/j.mtcomm.2025.112870· OSTI ID:3002835

^[1]; Smith, Tyler ^[1]; ^[1]; ^[1]; Elyas, Sana ^[1]; Nuttall, David ^[1]; ^[1]; ^[1]; ^[1]

Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

This study utilized additively reinforced thermoforming (ART) to enhance the thermomechanical properties of polyethylene terephthalate glycol (PETG) sheet. ART materials were produced by overprinting PETG/carbon fiber filament (PETG/CF) on neat PETG sheets at varying conditions. The mechanical properties of the PETG sheet, PETG/CF, and ART materials were assessed, showing that ART exhibited superior tensile strength and modulus of elasticity. The tensile strength and modulus in the x-direction for ART at 265°C were 57.32 ± 2.9 MPa and 3.41 ± 0.4 GPa, respectively, compared to 49.1 ± 0.5 MPa and 1.92 ± 0.09 GPa for neat PETG. Microstructural analysis revealed strong interfacial adhesion between layers, while thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and heat deflection temperature analysis provided insights into the ART material's thermoforming behavior, aiding design optimization for enhanced stiffness, reduced necking, and improved customization. In conclusion, this information can be used to design for the thermoforming operation.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO); USDOE Office of Science (SC)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 3002835

Journal Information:: Materials Today Communications, Journal Name: Materials Today Communications Vol. 46; ISSN 2352-4928

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Additive reinforcement
Characterization
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Thermoplastics

Optimizing processing conditions for additively reinforced thermoforming (ART) in convergent manufacturing

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