Path Planning and Bending Behaviors of 3D Printed Continuous Carbon Fiber Reinforced Polymer Honeycomb Structures

Continuous fiber reinforced polymer composites are widely used in load-bearing components and energy absorbers owing to their high specific strength and high specific modulus. The path planning of continuous fiber is closely related to its structural defects and mechanical properties. In this work, continuous fiber reinforced polymer honeycomb structures (CFRPHSs) with different printing paths were designed and fabricated via the fused deposition modeling (FDM) technique. The investigation of fiber dislocation at path corners was utilized to analyze the structural defects of nodes caused by printing paths. The lower stiffness nodes filled with pure polymer due to fiber dislocation result in uneven stiffness distribution. The bending performance and deformation modes of CFRPHSs with different printing paths and corresponding pure polymer honeycomb structures were investigated by three-point bending tests. The results showed that the enhancement effect of continuous fibers on the bending performance of honeycomb structures was significantly affected by the printing paths. The CFRPHSs with a staggered trapezoidal path exhibited the highest specific load capacity (68.33 ± 2.25 N/g) and flexural stiffness (627.70 ± 38.78 N/mm). In addition, the fiber distributions and structural defects caused by the printing paths determine the stiffness distribution of the loading region, thereby affecting the stress distribution and failure modes of CFRPHSs.