Cost-effective large scale 3D printing of continuous fibre-reinforced thermoplastic composites using UD tapes

acm7 Tracking Number 13

Additive manufacturing with continuous fibre-reinforced thermoplastic composites offers significant potential for producing high-strength, lightweight structures. In this research, a novel 3D printing device was developed to print thermoplastic composites reinforced with continuous fibres, embedded directly within the printed bead. Unlike conventional continuous fibre 3D printing methods that require costly pre-manufactured filaments, this approach allows the direct use of standard unidirectional tapes ranging from 6 to 10 mm in width, eliminating an additional production step and reducing costs. The key innovation of this technique lies in its cost-effectiveness and scalability, making large-scale 3D printing with continuous fibres more accessible for industrial applications. This study presents an overview of the developed printing process, focusing on the integration of continuous fibres within thermoplastic materials, process optimization, and the resulting mechanical performance. Experimental results demonstrate significant improvements in the mechanical performance of printed components compared to traditional 3D printing techniques. This work contributes to advancing large-scale additive manufacturing by providing a more economical and efficient method for printing high-performance composite structures.