Microwave-induced Enhancement of Interlayer Strength in FDM-printed Nylon6/Carbon Fiber Composites

Among 3D printing techniques, fused deposition modeling (FDM) is known for its design flexibility, rapid fabrication, and the ability to produce complex geometries without molds. However, weak interlayer adhesion often results in poor mechanical strength along the build (Z) direction, limiting its use in structural applications. Instead of altering printing parameters or switching technologies, we propose a simple microwave-irradiation post-treatment to enhance interlayer bonding in FDM-printed parts. By optimizing microwave power and exposure time, we significantly improved interlayer fusion while maintaining the original geometry. Cross-sectional microscopy before and after treatment confirmed markedly improved interlayer bonding (Unbonded interfacial area fraction: 56.82% → 15.51%; -41.31 percentage points, -72.7%). Correspondingly, the Z-direction tensile strength increased from 42.38 to 49.11 MPa (+6.73 MPa, +15.9%). This straightforward post-processing method effectively addresses a key limitation of FDM, thereby expanding its potential for structural and industrial applications.