Additive manufacturing of continuous fiber reinforced polymer composites: Design opportunities and novel applications

The development of additive manufacturing (AM) has revolutionized the fabrication process of continuous fiber reinforced polymer (CFRP) composites with its outstanding ability to create products that are complex in material, structure, and function. However, existing studies mostly focus on the manufacturing process without paying sufficient attention to exploring new design opportunities enabled by CFRP-AM. This paper outlines the design concept for additive manufacturing of continuous fiber reinforced polymer composites, aiming to improve existing products' performance and foster product innovations for future needs. More specifically, existing CFRPAM techniques are reviewed from the perspective of functional requirements. Design opportunities within the material, process, and structure domains are identified. Also, novel applications enabled by design for CFRP-AM on shape morphing, sensing, and energy storage are presented. The review concludes with a brief discussion and an outlook on future work.;The development of additive manufacturing (AM) has revolutionized the fabrication process of continuous fiber reinforced polymer (CFRP) composites with its outstanding ability to create products that are complex in material, structure, and function. However, existing studies mostly focus on the manufacturing process without paying sufficient attention to exploring new design opportunities enabled by CFRP-AM. This paper outlines the design concept for additive manufacturing of continuous fiber reinforced polymer composites, aiming to improve existing products' performance and foster product innovations for future needs. More specifically, existing CFRPAM techniques are reviewed from the perspective of functional requirements. Design opportunities within the material, process, and structure domains are identified. Also, novel applications enabled by design for CFRP-AM on shape morphing, sensing, and energy storage are presented. The review concludes with a brief discussion and an outlook on future work.