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<p>Continuous carbon fiber-reinforced polymer (CCFRP) composites offer exceptionally low density, high specific strength, and high specific stiffness. However, their further engineering applications are limited by intrinsic brittleness and poor damage tolerance. Inspired by the biological brick-and-mortar structure of nacre, this study used multi-material 3D printing to fabricate nacre-inspired CCFRPs. Different geometric parameters, including aspect ratio and waviness angle, were designed to investigate their roles in governing the mechanical response, damage tolerance, and shape recovery effects under primary and secondary quasi-static compression. The results show that the interlocking structure with a moderate aspect ratio exhibited superior initial compressive performance, and the specimen with<i> η</i> = 3 and <i>θ</i> = − 5° showed the best overall performance among the tested configurations with the peak compressive stress reaching 14.25 MPa. A performance inversion was observed during secondary compression: the initially optimal structures suffered severe irreversible internal damage and showed the lowest residual strength of 1.6 MPa, whereas structures that failed prematurely by macroscopic buckling or interfacial sliding retained better residual load-bearing capacity. While nacre-inspired CCFRPs exhibit over 98% macroscopic shape recovery driven by the hyperelastic and viscoelastic nature of the thermoplastic polyurethane (TPU) matrix, this restoration belies severe underlying microstructural degradation. This work reveals the trade-off between initial strength and subsequent damage tolerance, providing theoretical insights and design guidelines for developing next-generation, reusable, and highly damage-tolerant composite structures.</p>

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Effects of aspect ratio and waviness angle on the compressive properties and damage tolerance of 3D-printed nacre-inspired continuous carbon fiber composites

  • 期刊论文

  • 发表日期：

    2026年7月29日

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  • Wenfei Peng,
  • Jiaoyang Xu,
  • Yiyu Shao,
  • Tongya Shi

摘要

Continuous carbon fiber-reinforced polymer (CCFRP) composites offer exceptionally low density, high specific strength, and high specific stiffness. However, their further engineering applications are limited by intrinsic brittleness and poor damage tolerance. Inspired by the biological brick-and-mortar structure of nacre, this study used multi-material 3D printing to fabricate nacre-inspired CCFRPs. Different geometric parameters, including aspect ratio and waviness angle, were designed to investigate their roles in governing the mechanical response, damage tolerance, and shape recovery effects under primary and secondary quasi-static compression. The results show that the interlocking structure with a moderate aspect ratio exhibited superior initial compressive performance, and the specimen with η = 3 and θ = − 5° showed the best overall performance among the tested configurations with the peak compressive stress reaching 14.25 MPa. A performance inversion was observed during secondary compression: the initially optimal structures suffered severe irreversible internal damage and showed the lowest residual strength of 1.6 MPa, whereas structures that failed prematurely by macroscopic buckling or interfacial sliding retained better residual load-bearing capacity. While nacre-inspired CCFRPs exhibit over 98% macroscopic shape recovery driven by the hyperelastic and viscoelastic nature of the thermoplastic polyurethane (TPU) matrix, this restoration belies severe underlying microstructural degradation. This work reveals the trade-off between initial strength and subsequent damage tolerance, providing theoretical insights and design guidelines for developing next-generation, reusable, and highly damage-tolerant composite structures.