Process validation and performance evaluation of 3D printing continuous fiber reinforced thermoplastic composite corrugated sandwich structure

This study focuses on the process validation and performance evaluation of 3D-printed continuous fiber-reinforced thermoplastic composite corrugated sandwich structures. It explores their mechanical behavior under different structural designs and manufacturing process characteristics. Through real-time impregnation technology, continuous fibers were combined with thermoplastic resin to print both arc-shaped and trapezoidal corrugated sandwich structures, and their compressive strength was tested and analyzed through experimental testing. The results show that the trapezoidal sandwich structure exhibits higher compressive strength under compression loads, with a peak compressive strength value of 9.11Mpa. In contrast, the arc-shaped sandwich structure has a value of 4.76Mpa. Under the same conditions, the trapezoidal structure demonstrates superior load distribution capability and higher stiffness with lower deformation. The experiment investigated the impact of process parameters and fiber-resin bonding quality on structural performance in real-time impregnation technology, indicating that this process can effectively optimize material properties and offer good manufacturing flexibility.