3D Printing Methods of Fiber Reinforced Composites Based on Multi Extrusion Heads

SU Xuan; ZHANG Zhaohui; CHEN Xiaoyan

doi:10.3969/j.issn.1674-6457.2026.02.018

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (2) : 196-207. DOI: 10.3969/j.issn.1674-6457.2026.02.018

Additive Manufacturing

3D Printing Methods of Fiber Reinforced Composites Based on Multi Extrusion Heads

SU Xuan^1,*, ZHANG Zhaohui², CHEN Xiaoyan¹

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Abstract

The work aims to propose a high-performance multi-material integrated extrusion head and its control system to address the problems of mechanical performance dispersion and insufficient structural accuracy of printed components caused by asynchronous extrusion of multiple materials, uneven temperature field, and unstable interface bonding quality in the melt deposition molding of continuous carbon fiber composites, so as to achieve precise collaborative control of the printing process of composites. Firstly, based on the analysis of the flow characteristics of short fiber filaments and the online impregnation mechanism of continuous fibers, the design of a multi-channel extrusion head structure was completed. The extrusion head featured partitioned, independent temperature control modules to provide precise thermal management for extrusion printing of various materials. It also incorporated an integrated micro wire cutting mechanism, enabling precise fiber cutting and restart during the printing process. Secondly, an integrated printing control system was constructed to adjust the power of the heater in real time through a PID algorithm, and synchronously coordinate the three-axis motion platform, wire feeding motor, and fiber feeding servo mechanism. Finally, the mechanical properties of unreinforced matrix and continuous carbon fiber reinforced composite specimens were compared and analyzed with a universal testing machine. Experimental data showed that, compared with the unreinforced matrix, the mechanical properties of composites reinforced with continuous carbon fibers were significantly improved, with a tensile strength of 653.7 MPa and a tensile modulus of elasticity increased to 32 675.95 MPa. In conclusion, the proposed multi extrusion head design and control system effectively improves the printing quality and mechanical properties of continuous carbon fiber composites, achieves stable coordination and control of multi-material printing, and provides a reliable process solution for additive manufacturing of complex fiber-reinforced structures.

Key words

additive manufacturing / multi extrusion head / printing control system / fiber reinforced composites / design and optimization

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SU Xuan, ZHANG Zhaohui, CHEN Xiaoyan. 3D Printing Methods of Fiber Reinforced Composites Based on Multi Extrusion Heads[J]. Journal of Netshape Forming Engineering. 2026, 18(2): 196-207 https://doi.org/10.3969/j.issn.1674-6457.2026.02.018

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Funding

Natural Science Foundation of Jiangsu Province Basic Research Plan-Youth Fund Project (BK20230173); Basic Science (Natural Science) Research Project of Universities in Jiangsu Province (23KJB460031); Key Laboratory of Advanced Food Manufacturing Equipment Technology of Jiangsu Province (FM-202304); Jiangsu Industry University Research Project (BY20240828)