Three-dimensional printing of continuous carbon fiber-reinforced polymer composites via in-situ pin-assisted melt impregnation

Continuous carbon fiber-reinforced thermoplastics (cCFRTPs), which are popular due to their light weight and high strength, are typically fabricated using heavy and expensive equipment. Recently, three-dimensional (3D) printing has been used for efficient production of small parts of cCFRTPs. In this study, a new 3D-printing system was developed using in situ pin-assisted melt impregnation method in the printing head where melt impregnation is carried out right before the printing. Various printing conditions were investigated by evaluating the printability and degree of impregnation of carbon fibers. Finally, the tensile strength of printed specimens using the new printing system was compared with that of specimens printed using other printing methods, demonstrating the uniformly impregnated carbon fibers and cCFRTPs with superior mechanical properties.