Embedded 3D printing of UV-curable thermosetting composites with continuous fiber

Extrusion-based 3D printing methods with in-nozzle impregnation mechanisms have been extensively employed in the fabrication of continuous fiber composites. This study presents an innovative embedded 3D printing technique that addresses significant challenges associated with existing methods. The technique utilizes a deposition nozzle to precisely write continuous fibers below the resin. A laser beam is directed onto the resin surface, which simultaneously cures the resin around the fiber bundle. The printing method demonstrates its advantages in producing high-quality composite samples with well-aligned fibers, minimized void density, and outstanding mechanical properties. More importantly, it introduces several capabilities that are highly desirable in the fabrication of contemporary composites, but unattainable with existing methods, including the dynamic control of fiber volume fractions and the ability to change matrix materials during printing. Furthermore, it enables the printing of filaments along curved pathways and printing of overhanging filaments for hollow features without support materials. The developed printing method exhibits versatility in working with different commercially available feedstock resins and reinforcement fibers. It is anticipated to be an impactful approach for the future development of thermosetting composites with diverse structural or multifunctional applications.