The role of additive manufacturing in the study of carbon fiber-reinforced polymer composite

Carbon fiber (CF) is highly valued for its exceptional strength-to-weight relation, making it best for energy-efficient applications in aerospace, automotive, and construction sectors. Recent advancements in CF technology have reduced production costs, enhancing market growth. Carbon fiber-reinforced polymer (CFRP) composites offer benefits such as fatigue resistance, weight reduction, stiffness, and corrosion resistance. The choice of matrix material, particularly thermoplastics, impacts CFRP properties, with thermoplastics favored for recyclability and mass production. Fabrication techniques like filament winding and resin transfer molding ensure precise CF alignment but have complexities. Additive manufacturing (AM) methods, such as FDM, DLP, and SLA, provide design flexibility and efficiency. Recycling approaches, including thermal, mechanical, and chemical methods, address CFRP waste. This review offers an overview of AM technologies in CFRP manufacturing, focusing on advancements in continuous, short, and nano carbon fiber composites, their properties, manufacturing methods, and recycling techniques, as well as their applications and topological optimization.