Design and Extrusion-Based 3D Printing of Continuous Fiber Composites: Status, Challenges, and Opportunities

This perspective article summarizes recent advancements in extrusion-based 3D printing of continuous fiber-reinforced polymers (CFRPs). It focuses on manufacturing techniques and computational design methodologies. While fused deposition modeling has been the primary method for printing thermoplastic CFRPs, recent innovations have enabled the printing of thermoset CFRPs using direct ink writing or similar techniques. These printing processes are also integrated with robotic arms to dramatically enhance manufacturing capabilities. Additionally, there has been notable progress in enhancing computational design methodologies to simultaneously optimize fiber distribution and topology of 3D printed CFRPs. The article also discusses future directions aimed at improving mechanical properties, scalability, multifunctionality, and predictability in CFRP 3D printing, which offer valuable perspectives for the development of this transformative manufacturing approach.