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

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

doi:10.1016/j.mtcomm.2025.112870

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

Research output: Contribution to journal › Article › peer-review

Abstract

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. This information can be used to design for the thermoforming operation.

Original language	English
Article number	112870
Journal	Materials Today Communications
Volume	46
DOIs	https://doi.org/10.1016/j.mtcomm.2025.112870
State	Published - Jun 2025

Funding

This manuscript has been authored in part by UT-Battelle, LLC, under contract DE-AC05–00OR22725 with the US Department of Energy (DOE). The US government retains and the publisher, by accepting the article for publication, acknowledges that the US government retains a nonexclusive, paid-up, irrevocable, worldwide license to publish or reproduce the published form of this manuscript, or allow others to do so, for US government purposes. DOE will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-public-access-plan). The authors gratefully acknowledge support from the U.S. Department of Energy, Advanced Materials and Manufacturing Technologies Office under contract DE-AC05–00OR22725 with UT-Battelle, LLC.

Keywords

Additive reinforcement
Characterization
Convergent manufacturing
Polymer composite
Thermoforming
Thermoplastics

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10.1016/j.mtcomm.2025.112870

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@article{57ff759bb1a94e34a656b8fa492afb46,

title = "Optimizing processing conditions for additively reinforced thermoforming (ART) in convergent manufacturing",

abstract = "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. This information can be used to design for the thermoforming operation.",

keywords = "Additive reinforcement, Characterization, Convergent manufacturing, Polymer composite, Thermoforming, Thermoplastics",

author = "Talabi, \{Segun Isaac\} and Tyler Smith and Brittany Rodriguez and Ryan Ogle and Sana Elyas and David Nuttall and Vlastimil Kunc and Vipin Kumar and Hassen, \{Ahmed Arabi\}",

note = "Publisher Copyright: {\textcopyright} 2025",

year = "2025",

month = jun,

doi = "10.1016/j.mtcomm.2025.112870",

language = "English",

volume = "46",

journal = "Materials Today Communications",

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T1 - Optimizing processing conditions for additively reinforced thermoforming (ART) in convergent manufacturing

AU - Talabi, Segun Isaac

AU - Smith, Tyler

AU - Rodriguez, Brittany

AU - Ogle, Ryan

AU - Elyas, Sana

AU - Nuttall, David

AU - Kunc, Vlastimil

AU - Kumar, Vipin

AU - Hassen, Ahmed Arabi

PY - 2025/6

Y1 - 2025/6

N2 - 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. This information can be used to design for the thermoforming operation.

AB - 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. This information can be used to design for the thermoforming operation.

KW - Additive reinforcement

KW - Characterization

KW - Convergent manufacturing

KW - Polymer composite

KW - Thermoforming

KW - Thermoplastics

UR - https://www.scopus.com/pages/publications/105005957956

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DO - 10.1016/j.mtcomm.2025.112870

M3 - Article

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VL - 46

JO - Materials Today Communications

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ER -

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

Abstract

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Keywords

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