Fabrication process research of 3D-printed continuous carbon fiber reinforced nylon composite prepreg filaments

doi:10.19936/j.cnki.2096-8000.20260528.014

Abstract

Abstract: To enhance the resin impregnation efficiency and reduce porosity in continuous fiber-reinforced thermoplastic composites for additive manufacturing, thereby improving the mechanical properties of printed parts, this study employed a thermo-mechanical coupled process to fabricate continuous carbon fiber/nylon(CCF/PA6) prepreg filaments. Orthogonal experimental design was adopted to evaluate different parameter combinations, followed by range analysis of tensile properties, crystallinity, micromorphology, and porosity to determine the optimal forming parameters for different performance levels. Results demonstrated that fully impregnated filaments achieved a tensile strength of 691.37 MPa, a maximum crystallinity of 31.91%, and a minimum porosity of 1.28%. Furthermore, FDM printing validation using the optimized filaments revealed that lower layer thickness, reduced road spacing, and higher printing temperature significantly improved the mechanical performance of printed specimens, as confirmed by mechanical testing and fracture surface analysis.

Key words: carbon fiber, nylon, composite materials, pre-impregnated filaments, tensile properties, crystallinity, porosity

CLC Number:

TB332

WANG Yuxuan, LIAN Lixian, YANG Dong, HE Taijun, FAN Congze, SONG Wenzhe, CHEN Fang. Fabrication process research of 3D-printed continuous carbon fiber reinforced nylon composite prepreg filaments[J]. COMPOSITES SCIENCE AND ENGINEERING, 2026, 0(5): 104-115.

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