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<p>Aramid fibres serve as exceptional reinforcements in composite materials owing to their combination of high modulus, superior specific strength and low density. Their remarkable properties make them well-suited for additive manufacturing (AM) applications. However, their smooth, chemically inert surface limits fibre–matrix bonding. Surface modifications enhance surface roughness and chemical activity, improving adhesion and composite performance. Unlike conventional methods, AM offers precise control over material distribution, fibre alignment and complex geometries, enabling lightweight, strong structures. Aramid fibre-reinforced polymers produced through AM show enhanced tensile strength, superior impact resistance and enhanced thermal stability, rendering them highly advantageous for aerospace, automotive and defence industries. Fused filament fabrication and selective laser sintering, which are the recent advancements in AM technologies, have improved fibre dispersion and orientation in both thermoplastic and thermosetting matrices, while reducing material waste and supporting sustainability. Despite these benefits, challenges like fibre breakage, anisotropic mechanical properties and poor interfacial adhesion persist. Future research should focus on printing parameter optimization, developing novel fibre–polymer compatibilization techniques, and exploring hybrid reinforcements to further improve AM-fabricated aramid composites. As AM evolves, it holds significant potential to transform composite manufacturing through enhanced design flexibility, efficiency and mechanical performance.</p> Graphical abstract <p></p>

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Surface functionalization techniques for improved additive manufacturing of aramids

  • 期刊论文

  • 发表日期：

    2026年3月19日

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  • Deepali Sanjay Kulkarni,
  • Amol Indalkar,
  • Shruti Gupta,
  • Balasubramanian Kandasubramanian

摘要

Aramid fibres serve as exceptional reinforcements in composite materials owing to their combination of high modulus, superior specific strength and low density. Their remarkable properties make them well-suited for additive manufacturing (AM) applications. However, their smooth, chemically inert surface limits fibre–matrix bonding. Surface modifications enhance surface roughness and chemical activity, improving adhesion and composite performance. Unlike conventional methods, AM offers precise control over material distribution, fibre alignment and complex geometries, enabling lightweight, strong structures. Aramid fibre-reinforced polymers produced through AM show enhanced tensile strength, superior impact resistance and enhanced thermal stability, rendering them highly advantageous for aerospace, automotive and defence industries. Fused filament fabrication and selective laser sintering, which are the recent advancements in AM technologies, have improved fibre dispersion and orientation in both thermoplastic and thermosetting matrices, while reducing material waste and supporting sustainability. Despite these benefits, challenges like fibre breakage, anisotropic mechanical properties and poor interfacial adhesion persist. Future research should focus on printing parameter optimization, developing novel fibre–polymer compatibilization techniques, and exploring hybrid reinforcements to further improve AM-fabricated aramid composites. As AM evolves, it holds significant potential to transform composite manufacturing through enhanced design flexibility, efficiency and mechanical performance.

Graphical abstract