Preparation and Process Parameter Optimization of Continuous Carbon Fiber-Reinforced Polycarbonate Prepreg Filament

Continuous fiber-reinforced composite 3D printing (CFRC 3DP) has become a hot topic of interest for many experts and scholars. Continuous fiber-reinforced prepreg filament (CFRPF) for printing needs to be prepared in advance. In this paper, on the basis of the resin fusion impregnation theory, a fabrication device was designed for continuous carbon fiber-reinforced polycarbonate prepreg filament (CCFRPF). Then, according to the orthogonal test and the TOPSIS entropy weight optimization theory, the optimization method for CFRPF/PC preparation process parameters was proposed, and the relationship between the preparation process parameters and the performance indexes was discussed. The results show that when preparing CCFRPF/PC, the weight of diameter performance index is the largest, about 0.75. The optimal combination of process parameters for CCFRPF/PC is, respectively, 285 °C for the outlet mold temperature, 305 °C for the impregnation mold temperature, and 1 m/min for the winding speed. In this case, the diameter, roundness, minimum curvature radius and tensile strength of 0.375 mm, 29.4 μm, 9.775 mm and 1298 MPa were achieved, respectively.