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<p>To improve the overall performance and quality of 3D printed parts, recent research has focused on the development of high-performance composite materials and multi-axis 3D printing technology. This study proposes a conformal five-axis 3D printing process using continuous carbon fiber-reinforced composites (CCFRCs) for curved surfaces. Continuous carbon fiber (CCF) serves as the reinforcement, polylactic acid (PLA) as the matrix material, and polyvinyl alcohol (PVA) as the support material. A sandwich structure is employed to achieve both lightweight characteristics and mechanical enhancement. A five-axis dual-nozzle 3D printing platform was developed to realize the proposed process. The printing system was designed to enable precise deposition along curved geometries. Structural design and toolpath planning were carried out for typical curved components. In the experimental phase, planar standard specimens were first printed and tested to investigate the effect of different fiber layer counts on mechanical performance. Subsequently, typical spatial curved parts were fabricated and subjected to compression and bending tests. The results show that the proposed method effectively enhances the mechanical strength and surface quality of printed curved parts. The functional integrity of the five-axis platform and the feasibility of the proposed conformal printing process were successfully validated through experimental verification.</p>

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Research and implementation of a conformal five-axis 3D printing process for continuous carbon fiber reinforced composites on curved surfaces

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Qingxi Hu,
  • Mao Li,
  • Haiguang Zhang

摘要

To improve the overall performance and quality of 3D printed parts, recent research has focused on the development of high-performance composite materials and multi-axis 3D printing technology. This study proposes a conformal five-axis 3D printing process using continuous carbon fiber-reinforced composites (CCFRCs) for curved surfaces. Continuous carbon fiber (CCF) serves as the reinforcement, polylactic acid (PLA) as the matrix material, and polyvinyl alcohol (PVA) as the support material. A sandwich structure is employed to achieve both lightweight characteristics and mechanical enhancement. A five-axis dual-nozzle 3D printing platform was developed to realize the proposed process. The printing system was designed to enable precise deposition along curved geometries. Structural design and toolpath planning were carried out for typical curved components. In the experimental phase, planar standard specimens were first printed and tested to investigate the effect of different fiber layer counts on mechanical performance. Subsequently, typical spatial curved parts were fabricated and subjected to compression and bending tests. The results show that the proposed method effectively enhances the mechanical strength and surface quality of printed curved parts. The functional integrity of the five-axis platform and the feasibility of the proposed conformal printing process were successfully validated through experimental verification.