3D printing of continuous carbon fibre reinforced high-temperature epoxy composites

This study presents a novel high-temperature solid epoxy system and investigates its use for 3D printing of continuous carbon fibre reinforced thermoset composites. The solid epoxy system was formulated using a mixture of novolak epoxy resin and amine hardener. It was deposited on the continuous carbon fibres to produce impregnated filament, which was then used for fused filament fabrication (FFF) based 3D printing, followed by a curing process. The resulting printed composite exhibited a high glass transition temperature ( T g ) of 279.24 °C, along with a longitudinal tensile strength of 1006 MPa and a flexural strength of 431.8 MPa, making it suitable for high-temperature load-bearing applications. Additionally, a lightweight honeycomb composite structure was printed and cured in a 3D printed bespoke mould made from a high-temperature thermoplastic composite material. The final cured part demonstrated excellent thermal stability under isothermal loading at 200 °C, showcasing the potential of this system for advanced structural applications in aerospace and related fields. • A novel high-temperature solid epoxy system was formulated for 3D printing applications. • Exceptional thermal properties were achieved in cured composites, with a glass transition temperature of 279 °C. • A lightweight honeycomb composite structure demonstrated excellent stability under isothermal loading at 200 °C.