Experimental and Numerical Investigation of Tensile Performance in 3D ‐Printed Continuous Fiber‐Reinforced Composites With Various Printing Paths and Materials Combinations

ABSTRACT Continuous fiber‐reinforced composites (CFRCs) are promising materials for lightweight structures, yet conventional molding methods limit design flexibility and optimization potential. Additive manufacturing enables precise control of fiber trajectories and matrix combinations, offering new opportunities for customized structural design. Therefore, this study employed a combined experimental and numerical approach to investigate the tensile properties and failure mechanisms of 3D‐printed two‐matrix CFRCs with various printing paths and material combinations, with particular emphasis on single‐layer multi‐directional fiber architectures unique to 3D printing continuous fiber. A novel two‐step finite element (FE) modeling framework based on the embedded element technique was developed to accurately reproduce fiber trajectories and predict mechanical responses. The results reveal that continuous basalt fiber reinforced epoxy‐polyethylene terephthalate glycol with unidirectional 0° fibers exhibits the highest tensile strength of 290.90 MPa, while continuous carbon fiber reinforced epoxy‐short fiber reinforced polyamide shows superior interfacial bonding and post‐failure resistance. Among multi‐directional configurations, orthogonal grid patterns enhanced load transfer, whereas 90° fibers reduced mechanical efficiency. The validated FE framework provides a reliable tool for the structural optimization of 3D‐printed CFRCs and establishes a foundation for future extensions to FE methods and other mechanical responses.