Recent progress of 3D printed continuous fiber reinforced polymer composites based on fused deposition modeling: a review

Abstract

3D Printing, utilizing a layer-by-layer deposition of materials, is advantageous to manufacture parts as it involves fewer process steps, provides great flexibility for prototyping, especially of complex parts, and has low material waste. Yet, the mechanical properties of 3D printed parts have always been a concern due to the weak inter-layer bonding and rough surface. 3D printed continuous fiber reinforced polymer composites (CFRPCs) use continuous fiber reinforcements for the polymer matrix, which significantly improve the mechanical properties of printed parts. CFRPCs are widely used in aerospace, automobile, medical industry and other fields due to their excellent specific mechanical properties. Compared with other 3D printing technologies, fused deposition modeling (FDM) has the advantages of low cost and simple operation to fabricate CFRPCs. In this review article, the choices of various continuous fibers and matrix polymers and their effect on the performance of CFRPCs have been discussed. Furthermore, the latest equipment and methods to fabricate CFRPCs will be summarized, and the key parameters affecting the properties of CFRPCs analyzed. At the end, based on the related research, we critically highlight the challenges and opportunities associated with FDM of CFRPCs to point out the direction of future work.