Fused filament fabrication (FFF) of composites with compliant high-strength fibers could expand opportunities for the design and fabrication of complex flexible structures, but this topic has received limited attention. This study pursued the development of filaments consisting of ultra-high molecular weight polyethylene yarn (UHMWPE) embedded in a matrix of polycaprolactone (UPE/PCL) and successful 3D printing. The physical characteristics and printability of the filament were evaluated in terms of key parameters including spooling speed, temperature, fiber distribution (consolidated vs dispersed), and fiber volume fraction (4≤ Vf ≤30 %). An evaluation of the microstructure and tensile properties of the UPE/PCL was performed after processing and printing. Prior to printing, the filament exhibited an ultimate tensile strength (UTS) of 590±40 MPa with apparent fiber strength of 2.4 GPa. For the printed condition, the UTS reached 470±60 MPa and apparent fiber strength of 1.9 GPa. Fiber dispersion in the filament plays an important role on the printed properties and the potential for fiber degradation. Nevertheless, the strength of the UPE/PCL represents a new performance benchmark for compliant composites printed by FFF. This new material system can support applications where strength and toughness are key performance metrics in addition to flexibility. 
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                            PunchPrint: Creating Composite Fiber-Filament Craft Artifacts by Integrating Punch Needle Embroidery and 3D Printing
                        
                    
    
            New printing strategies have enabled 3D-printed materials that imitate traditional textiles. These filament-based textiles are easy to fabricate but lack the look and feel of fiber textiles. We seek to augment 3D-printed textiles with needlecraft to produce composite materials that integrate the programmability of additive fabrication with the richness of traditional textile craft. We present PunchPrint: a technique for integrating fiber and filament in a textile by combining punch needle embroidery and 3D printing. Using a toolpath that imitates textile weave structure, we print a flexible fabric that provides a substrate for punch needle production. We evaluate our material’s robustness through tensile strength and needle compatibility tests. We integrate our technique into a parametric design tool and produce functional artifacts that show how PunchPrint broadens punch needle craft by reducing labor in small, detailed artifacts, enabling the integration of openings and multiple yarn weights, and scaffolding soft 3D structures. 
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                            - Award ID(s):
- 2026286
- PAR ID:
- 10483025
- Publisher / Repository:
- ACM
- Date Published:
- Journal Name:
- 2023 CHI Conference on Human Factors in Computing Systems (CHI '23)
- ISBN:
- 9781450394215
- Page Range / eLocation ID:
- 1 to 15
- Format(s):
- Medium: X
- Location:
- Hamburg Germany
- Sponsoring Org:
- National Science Foundation
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