Additive Functionalization: Combining the Benefits of Additive Manufacturing and Conventional Composite Production by Overprinting

Abstract

Additive Manufacturing (AM) with thermoplastic polymers offers design flexibility, manufacturing agility and low tooling costs, making it especially interesting for aircraft interior. A new approach, additive functionalization, aims to combine thermoplastic AM with conventional thermoset composite production. By printing directly onto thermoset components, complex hybrid lightweight parts can be manufactured without additional tooling costs. A key challenge is achieving a strong bond between overprinted thermoplastic material and thermoset layers. This study investigates the effect of different thermoset surface modifications on the bond strength and demonstrates the concept by printing a thermoplastic rib onto a curved thermoset composite shell.