Additive Manufacturing of Carbon Fiber-reinforced Composites: A Review

Carbon fiber-reinforced composites (CFRCs) have been widely used in automotive, aerospace, sports equipment, and other industrial fields, due to the higher strength-to-weight ratio and modulus compared with metals and alloys. Innovations in additive-manufactured CFRCs have opened up new avenues for designing and manufacturing high-performance, low-cost complex composite structures. According to the structure and substrate type of carbon fiber, this paper firstly reviews the existing feasible technologies as well as their key elements and focuses on the research of additive manufactured CFRCs by fused deposition molding (FDM) and selective laser sintering (SLS). Furthermore, the typical applications and envisions of additive manufactured CFRCs were elaborated. Moreover, the existing challenges and problems are summarized from the aspects of materials, equipment, and software. In the future, more interdisciplinary research is needed on advanced materials, multiple processes, advanced equipment, and structural design, and there will be a broader research space for robot-assisted additive manufacturing and green manufacturing methods.