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<p>Additive manufacturing by fused deposition modeling (FDM) is an efficient technique for material conservation but often produces thermoplastic polymer components with inadequate strength due to defects. Continuous fiber composites printed by FDM can reduce these limitations and outperform short fiber composites and neat polymers in mechanical performance. This study incorporated continuous carbon fibers into a biodegradable polylactic acid (PLA) matrix and systematically investigated the effects of infill pattern, infill density, and layer thickness on flexural behavior. Micro‑computed tomography (Micro‑CT) scan showed that fiber orientation and distribution closely matched the slicing strategy. A Tetragrid pattern with 75% infill density and 0.35&#xa0;mm fiber layer thickness delivered the highest flexural strength of 70.04&#xa0;MPa and flexural modulus of 1348.77&#xa0;MPa. Fractographic analysis elucidated the dominant failure mechanisms and fiber–matrix interfacial behavior. These findings demonstrate that optimized continuous carbon fiber‑reinforced PLA composites are promising lightweight alternatives in applications requiring high strength‑to‑weight ratios.</p> Graphical abstract <p></p>

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Flexural performance and failure behavior of additively manufactured continuous carbon fiber-reinforced polylactic acid composites

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Naveen Kumar Chandrasekaran,
  • Venkatesan Subramani

摘要

Additive manufacturing by fused deposition modeling (FDM) is an efficient technique for material conservation but often produces thermoplastic polymer components with inadequate strength due to defects. Continuous fiber composites printed by FDM can reduce these limitations and outperform short fiber composites and neat polymers in mechanical performance. This study incorporated continuous carbon fibers into a biodegradable polylactic acid (PLA) matrix and systematically investigated the effects of infill pattern, infill density, and layer thickness on flexural behavior. Micro‑computed tomography (Micro‑CT) scan showed that fiber orientation and distribution closely matched the slicing strategy. A Tetragrid pattern with 75% infill density and 0.35 mm fiber layer thickness delivered the highest flexural strength of 70.04 MPa and flexural modulus of 1348.77 MPa. Fractographic analysis elucidated the dominant failure mechanisms and fiber–matrix interfacial behavior. These findings demonstrate that optimized continuous carbon fiber‑reinforced PLA composites are promising lightweight alternatives in applications requiring high strength‑to‑weight ratios.

Graphical abstract