Jevan Furmanski, Andrew Abbott, G. P. Tandon, Mark Flores, Philip Barnett, Marco Salviato, Jeffery Baur, Dennis Butcher

Research output: Chapter in Book/Report/Conference proceedingConference contribution


Continuously-reinforced composite additive manufacturing (CC-AM) is set to revolutionize the manufacturing and design of complex high-strength, low-weight structures. Longitudinal tensile strengths of CC-AM have been reported exceeding 1500 MPa with minimal porosity, making this system available for structural applications. However, there remain a number of morphological non-idealities that are unique to the CC-AM process that challenge the performance of a complex AM build. These can be categorized into material non-idealities (fiber clustering, resin-rich zones, matrix quality) and topological constraint non-idealities (joint design constraints, minimum path radius, tow cuts). Furthermore, for UV snap-cured carbon fiber CC-AM, limited penetration of the incident UV through the carbon fiber tow presents a challenge to optimal in-situ curing. The present work lays out these challenges, with specific case examples for material built with the CF3D system (Continuous Composites Inc.) using T-1100 12K carbon fiber tows and a UV snap curing acrylate resin. Most of the issues highlighted are inherent to CC-AM, so the recommendations for future development to mitigate the various non-idealities are expected to translate to other CC-AM technologies, such as those using a thermoplastic polymer.

Original languageEnglish (US)
Title of host publicationSAMPE 2023 Conference and Exhibition
PublisherSoc. for the Advancement of Material and Process Engineering
ISBN (Electronic)9781934551431
StatePublished - 2023
EventSAMPE 2023 Conference and Exhibition - Seattle, United States
Duration: Apr 17 2023Apr 20 2023

Publication series

NameInternational SAMPE Technical Conference


ConferenceSAMPE 2023 Conference and Exhibition
Country/TerritoryUnited States


  • Additive manufacturing
  • composite
  • continuous fiber
  • defect

ASJC Scopus subject areas

  • General Materials Science
  • Mechanics of Materials
  • Mechanical Engineering


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