Zheng Haoyuan, Zhu Shaowei, Chen Liming, Wang Lianchao, Zhang Hanbo, Wang Peixu, Sun Kefan, Wang Haorui, Liu Chengtao
College of Aerospace Engineering, Chongqing University, Chongqing 400030, China.
State Key Laboratory of Coal Mine Disaster Dynamics and Control, Chongqing University, Chongqing 400030, China.
Polymers (Basel). 2025 Jun 9;17(12):1601. 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.
近年来，三维（3D）打印连续纤维增强聚合物（CFRP）技术的快速发展为高性能复合材料的定制制造提供了新策略。本文综述系统总结了该技术在材料体系、加工方法、力学性能调控及功能应用方面的研究进展。在材料方面，分析聚焦于碳纤维、玻璃纤维和天然纤维的性能特点及应用场景，同时讨论了聚醚醚酮（PEEK）等热塑性基体的加工行为。在工艺层面，比较了熔融沉积建模（FDM）和光聚合技术的优缺点，重点阐述了它们对纤维-基体界面的影响。综述进一步研究了纤维取向、体积分数等参数对力学性能的调控机制，以及电导率和自传感能力等功能设计的实现途径。全面分析了航空航天轻质结构和汽车吸能部件中的应用案例。突出了当前面临的挑战，并提出了未来发展方向，包括人工智能（AI）驱动的工艺优化和多材料混合制造。本文综述旨在全面评估3D打印CFRP技术的当前成果，并对现有挑战进行前瞻性分析，为加速3D打印CFRP技术从实验室研究向工业规模应用的转化提供系统参考。
