Influence of Printing Parameters and Paths on Warpage in 3D Printing of Continuous Carbon Fiber Composites

ABSTRACT The 3D printing of continuous carbon fiber reinforced thermoplastic composites (C‐CFRTP) enables the integrated manufacturing of lightweight, high‐strength components with complex structures. However, non‐negligible warpage deformation remains a limitation for C‐CFRTP parts. Although printing parameters and paths greatly influence warpage, the limited understanding of this impact hinders process optimization. In this study, the effects of process parameters such as base temperature, nozzle temperature, and printing speed on the warpage of 3D printed C‐CFRTP components were investigated. The temperature gradients experienced during printing were quantitatively characterized, the mechanisms driving warpage variations were analyzed, and the effects of each process parameter were clarified. Finally, the printing path (0°/0°, 0°/90°, and −45°/45°) was optimized for minimum deformation. The results showed that increasing the base temperature and printing speed while decreasing the nozzle temperature reduces the temperature gradient experienced by the printed parts, promotes uniform shrinkage and stress relaxation, thereby significantly minimizing warpage. Optimal warpage reduction was achieved by simultaneously controlling thermal gradients and stress distribution through fiber orientation, and the warpage under the −45°/45° printing path was the lowest, only 12% of that under the 0°/0° path. This work provides valuable guidance for reducing the warpage deformation of 3D printed C‐CFRTP components.