Optimization and assessment of CF/PEEK-PEEK composite shell manufactured by the laser-assisted in situ consolidation integrated with material extrusion process

The CF/PEEK-PEEK shell was manufactured through an integrated manufacturing process that merged material extrusion with laser-assisted in situ consolidation methods. A comprehensive finite element (FE) simulation was designed to systematically assess the effectiveness of introducing a CF/PEEK hoop stratification for PEEK lining with different length-to-diameter and thickness-to-diameter ratios. The simulation not only confirmed a noteworthy strengthening effect on the support after introducing the CF/PEEK hoop stratification, but also revealed that a smaller length-to-diameter ratio and a larger thickness-to-diameter ratio significantly enhanced the PEEK lining's resistance to deformation induced by the roller force. Building upon these findings, further simulations explored the optimal roller force for the PEEK lining with specified geometry. Additionally, research into manufacturing paths using laser-assisted in situ consolidation technique, including multi-stratification hoop and helical configurations, was conducted. To validate the accuracy of the simulation, computed tomography (CT) imaging was employed to assess the PEEK lining's deformation. This comparison confirmed the agreement between the simulated and actual deformation of the PEEK lining. Finally, the complete manufacturing of the CF/ PEEK-PEEK shell provided definitive validation of the design and its associated reliability assessment.