3D Printing Continuous Fiber Reinforced Polymers: A Review of Material Selection, Process, and Mechanics-Function Integration for Targeted Applications

• Published in: Polymers Vol. 17; no. 12; p. 1601
• Main Authors: Zheng, Haoyuan, Zhu, Shaowei, Chen, Liming, Wang, Lianchao, Zhang, Hanbo, Wang, Peixu, Sun, Kefan, Wang, Haorui, Liu, Chengtao
• Format: Journal Article
• Language: English
• Published: Switzerland MDPI AG 09.06.2025; MDPI
• Subjects: 3-D printers; 3D printing; Analysis; Artificial intelligence; Carbon fiber reinforced plastics; Carbon fibers; Chemical processes; Composite materials; Continuous fibers; Electrical resistivity; Energy absorption; Fiber orientation; Fiber reinforced polymers; Fiber-matrix interfaces; Fibers; Fused deposition modeling; Glass fiber reinforced plastics; Heat resistance; Identification and classification; Load; Manufacturing; Materials selection; Mechanical properties; Methods; Optimization; Performance characteristics; Photopolymerization; Polyether ether ketones; Polymers; Process controls; Regulatory mechanisms (biology); Review; Sustainable materials; Tensile strength; Thermoplastics; Three dimensional printing; China; functional applications; process; continuous fiber reinforced polymers; material selection; 3D printing; mechanical properties
• ISSN: 2073-4360; 2073-4360
• DOI: 10.3390/polym17121601

In recent years, the rapid development of three-dimensional (3D)-printed continuous fiber-reinforced polymer (CFRP) technology has provided novel strategies for customized manufacturing of high-performance composites. This review systematically summarizes research advancements in material systems, processing methods, mechanical performance regulation, and functional applications of this technology. Material-wise, the analysis focuses on the performance characteristics and application scenarios of carbon fibers, glass fibers, and natural fibers, alongside discussions on the processing behaviors of thermoplastic matrices such as polyetheretherketone (PEEK). At the process level, the advantages and limitations of fused deposition modeling (FDM) and photopolymerization techniques are compared, with emphasis on their impact on fiber–matrix interfaces. The review further examines the regulatory mechanisms of fiber orientation, volume fraction, and other parameters on mechanical properties, as well as implementation pathways for functional designs, such as electrical conductivity and self-sensing capabilities. Application case studies in aerospace lightweight structures and automotive energy-absorbing components are comprehensively analyzed. Current challenges are highlighted, and future directions proposed, including artificial intelligence (AI)-driven process optimization and multi-material hybrid manufacturing. This review aims to provide a comprehensive assessment of the current achievements in 3D printing CFRP technology and a forward-looking analysis of existing challenges, offering a systematic reference for accelerating the transformation of 3D printing CFRP technology from laboratory research to industrial-scale implementation.