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<p>Fused deposition modeling is an additive manufacturing technique widely used for thermoplastic fabrication; however, the resulting parts often exhibit limited mechanical performance due to inherent process-induced defects. Reinforcing polymers with continuous fibers can significantly enhance their load-bearing capability. In this study, continuous carbon fiber-reinforced polylactic acid composites were fabricated using an Anisoprint A4 composer. Micro-computed tomography was used to assess porosity and fiber orientation, confirming the structural integrity of embedded fibers. The influence of process parameters on tensile properties was investigated. Results showed that a rhombic grid pattern with 75% infill and 0.34&#xa0;mm thickness optimized tensile strength, while 50% infill and 0.36&#xa0;mm thickness optimized stiffness. Fractographic analysis revealed failure mechanisms and fiber–matrix interfacial interactions. The findings suggest that additively manufactured continuous carbon fiber composites have the potential to replace conventional composites and lightweight metals in specific applications requiring high strength-to-weight ratios.</p> Graphical abstract <p></p>

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Tensile and microstructural characterization of additively manufactured continuous carbon fiber-reinforced polylactic acid composites

  • 期刊论文

  • 发表日期：

    2025年11月23日

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  • Naveen Kumar Chandrasekaran,
  • Venkatesan Subramani

摘要

Fused deposition modeling is an additive manufacturing technique widely used for thermoplastic fabrication; however, the resulting parts often exhibit limited mechanical performance due to inherent process-induced defects. Reinforcing polymers with continuous fibers can significantly enhance their load-bearing capability. In this study, continuous carbon fiber-reinforced polylactic acid composites were fabricated using an Anisoprint A4 composer. Micro-computed tomography was used to assess porosity and fiber orientation, confirming the structural integrity of embedded fibers. The influence of process parameters on tensile properties was investigated. Results showed that a rhombic grid pattern with 75% infill and 0.34 mm thickness optimized tensile strength, while 50% infill and 0.36 mm thickness optimized stiffness. Fractographic analysis revealed failure mechanisms and fiber–matrix interfacial interactions. The findings suggest that additively manufactured continuous carbon fiber composites have the potential to replace conventional composites and lightweight metals in specific applications requiring high strength-to-weight ratios.

Graphical abstract