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<p>Continuous fibre composites 3D printing offers high design flexibility and mold-less integrated manufacturing advantages, making it highly promising for applications in aerospace, automotive, and other industries. However, inadequate impregnation results in poor mechanical properties are a key constraint to the application and development of 3D printed continuous fibre composites. To address this challenge, this study introduced a novel hybrid-dispersion impregnation (HDI) 3D printing process. This innovative process enables the real-time blending of dispersed reinforcing fibres (e.g., Kevlar) with thermoplastic matrix fibres (e.g., nylon) by incorporating a fibre dispersion module into the print head. This integration enhances the contact area between fibres and the matrix, improving resin impregnation throughout the composite. Experimental results indicated that the flexural strength and modulus of the composites fabricated using the HDI process reached 270.17 and 3.41 GPa, respectively, marking a notable enhancement of 36% and 40% compared to the undispersed specimens. Microscopic characterization confirmed that the HDI increased the fibre dispersion in the 3D printed composites and reduced the resin impregnation defects, resulting in the performance enhancement of the 3D printed composites. This study provides a theoretical basis and technical approach for the high-performance fabrication of continuous fibre-reinforced composites.</p>

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Hybrid-dispersion impregnation for 3D-printed continuous fibre composites: the processing and mechanical properties

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Yanming Ai,
  • Hanbiao Wang,
  • Zhanghao Hou,
  • Dingxing Zhi,
  • Zhengxian Guo,
  • Xiaokai Li,
  • Zhonghao Liu,
  • Huifa Shi

摘要

Continuous fibre composites 3D printing offers high design flexibility and mold-less integrated manufacturing advantages, making it highly promising for applications in aerospace, automotive, and other industries. However, inadequate impregnation results in poor mechanical properties are a key constraint to the application and development of 3D printed continuous fibre composites. To address this challenge, this study introduced a novel hybrid-dispersion impregnation (HDI) 3D printing process. This innovative process enables the real-time blending of dispersed reinforcing fibres (e.g., Kevlar) with thermoplastic matrix fibres (e.g., nylon) by incorporating a fibre dispersion module into the print head. This integration enhances the contact area between fibres and the matrix, improving resin impregnation throughout the composite. Experimental results indicated that the flexural strength and modulus of the composites fabricated using the HDI process reached 270.17 and 3.41 GPa, respectively, marking a notable enhancement of 36% and 40% compared to the undispersed specimens. Microscopic characterization confirmed that the HDI increased the fibre dispersion in the 3D printed composites and reduced the resin impregnation defects, resulting in the performance enhancement of the 3D printed composites. This study provides a theoretical basis and technical approach for the high-performance fabrication of continuous fibre-reinforced composites.