Mechanical performance of 3D-printed continuous fibre Onyx composites for drone applications: An experimental and numerical analysis

As drone technology grows in popularity, its application to automate aspects of society is increasing at a similar rate, where drones are now being trialled for delivering payloads over short distances. In order to progress the technology, 3D composite printing is being used to develop complicated parts for improved aerodynamic design that can be produced efficiently, where the resultant composite part has high specific strength and rigidity. This article reports 3D printing of high specific strength, high-temperature Polyamide 6 (Onyx), continuous glass-fibre reinforced Onyx, and carbon-fibre reinforced Onyx composites and characterising their mechanical and fracture behaviour. The Onyx + CF composites displayed up to 1243 % and 1344 % improvement in Young's modulus and tensile strength over neat Onyx samples. The flexural strength of Onyx + CF samples was up to 316.6 % higher than the flexural strength of the neat Onyx sample. SEM micrographs showed a strong bond between the hydration products and the carbon fibres, increasing their tensile and flexural strengths by preventing micro-crack propagation through fibre pull-out and breaking. The statistical analysis was conducted to ensure the validity of the results for the population and establish stress-strain relations, along with estimating errors. In addition, the carbon-fibre-reinforced Onyx composite was compared with commercially used alternatives for producing drone components. Finally, a finite element model was developed using a numerical homogenisation approach and validated to predict the tensile and flexural behaviour of Onyx and carbon-fibre reinforced Onyx samples. This study provides a direction for the next generation of drone manufacturers.