Line width prediction and mechanical properties of 3D printed continuous fiber reinforced polypropylene composites

A novel 3D printing process was used to fabricate continuous carbon fiber-reinforced polypropylene (CCF/PP) composites. In this study, a prediction model for the line width of 3D printed CCF/PP composites was developed based on the material conservation principle. According to this model, the correspondence rule between the process parameters and the fiber volume fraction of the sample was established. The accuracy of the prediction model was verified by monofilament printing experiments, and the maximum error of line width was 9.72%. Furthermore, the effects of process parameters on the flexural properties, tensile properties and interlaminar shear strength (ILSS) of 3D printed CCF/PP composites were investigated. The flexural strength of the sample reached 99.94 MPa and the flexural modulus reached 14.91 GPa. The maximum ILSS of the sample was 9.78 MPa, and the maximum tensile strength and modulus were 402.86 MPa and 43.64 GPa. The advantages of this process in terms of low manufacturing cost and trajectory flexibility could make it a good prospect for its application.