| Abstract | Thermoplastic advanced composites were prepared by melt compounding of an amorphous polyetherimide (PEI) matrix, recycled carbon fibres (rCFs), and Thermal Black (TB) particles followed by extruding the compounded composites and hybrids into filaments for FFF 3D printing. The effect of rCF and TB contents on the mechanical, rheological, and thermal performance of the PEI composites were evaluated. X-ray micro-tomography was carried out to assess on the porosity contents and, as well, on the rCF orientations in the initial extruded filaments and after their passage througth the nozzle of the 3D printer. At the incorporation of 20 wt.% rCF, the tensile modulus of injection molded specimens increased from 3200 MPa up to 6180 MPa, and the tensile strength increased from 74 MPa up to 103 MPa, respectively. X-ray micro-tomography results illustrated that the incorporation of rCF led to a porosity formation of about 17 % in the filaments. The length of the rCF was reduced from 6 mm down to around 30 µm due to the repetitive shear forces applied during the different steps specific to filament manufacturing process. Incorporation of TB provided higher flexibility, improved fibre-matrix adhesion, and helped to decrease the cost while preserving the advanced composites performance. |
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