To reduce the porosity of 3D printing continuous fiber reinforced polymer (CFRP) composites and improve the degree of resin impregnation on fibers, it is of great necessity to conduct research on the preparation and 3D printing performance of melt-impregnated continuous fiber prepreg filaments, as well as develop integrated fiber prepreg equipment. With glass fiber (GF) and carbon fiber (CF) as reinforcement, and polycarbonate (PC) as matrix, this study aims to develop a melt-impregnated prepreg wire preparation process and study the influence of the impregnation process on prepreg wire properties. Besides, using prepreg yarn as the raw material, this study is aimed at studying the effect of 3D printing forming process parameters on the fiber content, porosity and mechanical properties as well. The results indicated that when the tensile strength of continuous glass fiber reinforced polycarbonate (CGF/PC) prepreg filament was 627.8 MPa, the printing temperature was 260°C, the layering thickness was 0.10 mm, the scan spacing was 1.0 mm, the fiber content of continuous carbon fiber reinforced polycarbonate (CCF/PC) composite was 28.66vol%, the tensile strength and modulus were respectively 644.8 MPa and 85.6 GPa, and the optimized porosity was 3.87%. When the printing temperature was 280°C, the layering thickness was 0.14 mm, and the scan spacing was 1.2 mm, the fiber content of continuous glass fiber reinforced polycarbonate (CGF/PC) composite turned out to be 51.35vol%, the tensile strength and modulus were respectively 381.4 MPa and 23.6 GPa, and the optimized porosity was 4.41%.
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