Additive manufacturing of continuous fiber reinforced polymer composites: Process planning and intelligent control

Abstract

In the evolving additive manufacturing (AM) field, fiber-reinforced composites—particularly those with continuous fibers—are recognized for their superior mechanical properties. However, Continuous Fiber-Reinforced Polymer Composites (CFRPCs) produced via Material Extrusion (MEX) often exhibit limited structural complexity, restricting their performance potential. This limitation arises primarily from significant challenges in process planning, including fragmentation from intricate design features, excessive cutting points caused by complex geometries, disrupted fiber continuity from fiber cutting, and unfavorable fiber orientation due to sharp contours. This study reviews the process planning and control strategies for CFRPCs-MEX, focusing on overcoming manufacturing constraints and addressing the research gap in slicing and path planning. Initially, CFRPCs-MEX is introduced, highlighting the importance of process planning in mitigating these challenges. Key constraints are identified and categorized, including fiber orientation, continuity, warpage, bonding, and quality-related challenges, followed by a discussion of their impacts on the printing process. This review systematically presents strategies for optimizing dimensional accuracy, enhancing mechanical properties, and enabling multifunctional design. Furthermore, applications, challenges, and emerging trends are explored, including advances in slicing software, multi-axis system planning, AI-enhanced strategies, and process monitoring and control. This review advances process planning techniques by addressing these challenges, paving the way for more efficient, cost-effective, and intelligent production in the CFRPCs-MEX industry.