Research progress on process defects and failure behaviors of continuous fiber-reinforced composite materials via 3D printing

Constraint-free design, rapid production, and the absence of mold requirements are just a few of the reasons why continuous fiber-reinforced 3D printing (CFR3DP) has emerged as one of the most innovative advanced composite manufacturing technologies nowadays. This study examines the recent developments in research concerning process defects and the failure behaviors of CFR3DP. In order to systematically categorize the printing process, the notion of "dry/wet/dry-wet-mixed" has been introduced, with an emphasis on the three distinct groups of defects that may be introduced during the additive manufacturing process. Following this, an analysis was conducted to summarize the failure behaviors of CFR3DP while also identifying the primary causes of failure. In conclusion, we propose the prospect of CFR3DP with respect to cost reduction, efficiency, the mitigation of process defects, and improvement of failure mode.