Incorporation of Laser Cutter in the Light‐Assisted 3D Printing of Continuous Carbon Fiber Reinforced Thermoset Composites

ABSTRACT Continuous carbon fiber reinforced (CCFR) thermoset composites have broad applications in aerospace and other industries due to their high specific strength, stiffness, and thermal stability. 3D printing introduces cost‐effectiveness and design flexibility into their manufacturing processes. The light‐assisted direct ink write (DIW) printing process shows promise for manufacturing CCFR composites with low‐viscosity thermoset resin. However, fiber loop formation during nozzle direction changes presents a major challenge to achieving finished edges in complex parts with continuous fiber reinforcement. Additionally, printing complex objects with internal features, such as holes, is challenging due to fiber loop formation. This research addressed the fiber loop issue by introducing CO ₂ laser‐cutting assisted 3D printing technology for CCFR composites. CO ₂ laser cutting was implemented after printing each layer to achieve the desired shape and eliminate fiber loops at the edges. The unidirectionally 3D printed composites produced using this technology were mechanically characterized, exhibiting a tensile strength of 671 ± 43 MPa and a tensile modulus of 60 ± 3.9 GPa, with a fiber volume fraction of 28.8% ± 2%. These 3D printed composites demonstrated mechanical properties comparable to conventionally manufactured composites.