3D-Printed Continuous Fiber Composites: An Overview of Materials, Systems and Processes

lssue 4, Volume 2
Part of Special Issue Selected Papers from the 4th International Conference on 3D Printing & Additive Manufacturing
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3D-Printed Continuous Fiber Composites: An Overview of Materials, Systems and Processes

Ricardo Mello Di Benedetto 1,* Anderson Janotti 2 Thiago de Freitas Silvano 1 Luiz Claudio Pardini 3 Ilaria Cacciotti 4 Francesca Nanni 5 Antonio Carlos Ancelotti Junior 1
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1
Institute of Mechanical Engineering, Federal University of Itajubá—UNIFEI, Av. BPS, NTC—Composite Technology Center, 1303, Itajubá 37500-903, MG, Brazil
2
Department of Materials Science & Engineering, University of Delaware—UDEL, Newark, DE 19716, USA
3
Aeronautical Institute of Technology—ITA, Praça Marechal Eduardo Gomes, 50-Vila das Acácias, São José dos Campos 12228-900, SP, Brazil
4
Engineering Department, University of Niccolò Cusano, Via Don Carlo Gnocchi, 3, 00166 Roma, Italy
5
Department of Enterprise Engineering, University of Rome Tor Vergata, Via Cracovia 50, 00133 Roma, Italy
*
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Received: 10 October 2025 Revised: 05 November 2025 Accepted: 24 November 2025 Published: 16 December 2025

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© 2025 The authors. This is an open access article under the Creative Commons Attribution 4.0 International License (https://creativecommons.org/licenses/by/4.0/).

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Adv. Mat. Sustain. Manuf. 2025, 2(4), 10018; DOI: 10.70322/amsm.2025.10018
ABSTRACT: 3D-printed composites represent a cutting-edge advancement in additive manufacturing, offering the ability to fabricate high-strength, lightweight structures by embedding continuous fibers within a single deposition process. This innovative approach significantly enhances the mechanical performance of printed parts compared to traditional polymer-based 3D printing. In this article, we present a structured review of recent developments in 3D-printed composite technologies. The discussion is organized into three key areas: (i) the types and properties of continuous fibers used in 3D printing, (ii) the underlying mechanisms and systems that enable fiber deposition, and (iii) emerging strategies involving commingled materials that integrate reinforcement and matrix components at the filament level. This review aims to provide a comprehensive understanding of the current state and future directions of continuous fiber-reinforced additive manufacturing.
Keywords: 3D-printer; Continuous fibers 3D-printed materials
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