A comprehensive review of laser-assisted manufacturing processes for thermoset composites: Physical behavior, fundamental mechanisms of the process, and applications

Thermoset composites like Carbon fiber-reinforced thermoset plastic (CFRTS) have significantly transformed the aviation, automotive, and construction sectors due to their lightweight nature, exceptional stiffness-to-strength ratio, corrosion resistance, and enhanced thermal stability, particularly when cross-linking thermosets are used as matrix materials. Despite these advantages, traditional manufacturing methods often struggle to achieve precise fabrication control and optimize material properties, creating a critical gap in the effective production of these composites. In contrast, laser-assisted manufacturing (LAM) presents a promising alternative, leveraging the unique capabilities of laser energy for accurate material processing. This review systematically examines recent advancements in LAM techniques for carbon fiber-reinforced thermoset composites, addressing the underlying principles, diverse processes, and applications within the automotive and aerospace industries. Specifically, it explores the intricate mechanisms by which laser processing enhances the precision and quality of composite fabrication, including the effects of laser parameters on material properties and their implications for end-use performance. The novelty of this study lies in synthesizing existing knowledge while highlighting significant research gaps in the current literature, such as the limited investigation of laser-material interactions specific to thermoset composites and the need for standardized testing methodologies. Furthermore, this review identifies opportunities for interdisciplinary research, combining insights from materials science, mechanical engineering, and manufacturing technology to develop innovative solutions that maximize the potential of laser-assisted manufacturing. By elucidating the physical behavior of thermoset composites and evaluating the effectiveness of laser processing, this study not only contributes to a deeper understanding of this rapidly evolving field but also serves as a roadmap for future research directions. It emphasizes the importance of collaborative efforts to overcome existing challenges and optimize the integration of laser technology in composite manufacturing, thereby fostering advancements that could lead to more sustainable and efficient production practices.