The effect of fiber trajectory continuity in 3D printing on X‐band microwave absorption performance under different structural parameters

Abstract To address the challenge of maintaining the internal continuity of carbon fibers in microwave absorption structures produced through conventional methods, this study introduces the interrupted fiber segment array (IFSA) model and the continuous fiber path (CFP) model, which are employed to examine the effect of carbon fiber trajectory continuity within printed layers on microwave absorption performance under different structural parameters. Validation and further insights were achieved through microwave absorption performance tests and surface morphology analyses of the specimens. The findings indicate that the conductive pathways formed by the carbon fibers in the CFP model optimize impedance matching and enhance conductive loss, thereby achieving higher absorptivity than the IFSA model. Absorptivity is maximized when the fiber orientation is 0°. Under these conditions, a fiber spacing of 1.5 mm, a layer thickness of 0.2 mm, and a two‐layer or three‐layer structure are identified as optimal. This study underscores the advantages of continuous fiber 3D printing technology in the fabrication of microwave absorption structures. Highlights CFP model has higher absorptivity than IFSA model. Continuous carbon fiber conductive pathway enhances conductivity loss. The polarization sensitivity of CF/PLA specimens is strong. 3D printing impacts absorptivity via structural parameters and surface form.