Hybridizing Additive Manufacturing with Continuous Fiber Reinforced Thermoplastic Composites

Large Area Additive Manufacturing (LAAM) enables the rapid production of thermoplastic polymer structures but suffers from significant anisotropy and 3D printability limitations. These limitations often require additional material and time in order to incorporate supporting structures. This research explores the integration of continuous fiber reinforced thermoplastics (CFRTP) with LAAM structures. A series of experimental trials were performed, which demonstrate the feasibility and benefits of CFRTP integration, as it can improve structural strength, lightweighting, and manufacturing flexibility. The findings suggest that CFRTP integration can significantly enhance LAAM by reducing material usage, improving mechanical properties, and expanding design possibilities. While further research is needed to optimize the process for specific applications, this process of Hybrid Advanced Additive Manufacturing (HAAM) presents a promising approach for advancing large-scale additive manufacturing.