A review on the fused deposition modelling of fibre-reinforced polymer composites: Influence of process parameters, pre-processing and post processing techniques

Additive manufacturing is one of the latest manufacturing techniques that has gained universal recognition due to its material conservation nature. Fused deposition modelling (FDM) is an additive manufacturing technique that employs material extrusion to build components layer by layer. Thermoplastic polymers are used in FDM, and the components created are anisotropic and porous. Composite materials are used to improve the quality of the components. This article reviews recent research focused on the enhancement of the mechanical performance of composites produced by FDM. The influence of process parameters, type of fibre reinforcement (short and continuous fibres), pre-processing, process modification and post-processing techniques is analysed. Short fibres improved the mechanical performance of components, irrespective of the polymer matrix. Short fibres offered dimensional stability to the components, besides improving mechanical performance. Continuous fibres produce components with superior mechanical properties than short fibre composites. Continuous fibre reinforcement is the most effective reinforcement for fabricating structural and functional components in FDM. The importance of pre-processing, process modification and post-processing techniques in improving the mechanical characteristics of the components is discussed. In addition, this review identifies the significant challenges and perspectives for the future development of FDM technology in fibre-reinforced composites.