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Microstructural and mechanical performance of continuous carbon fiber-reinforced filaments via melting impregnation: process and equipment optimization
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DOI：10.1016/j.addma.2026.105222.png)
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Abstract
En 中文
This study aims to investigate the single‑fiber bundle melting impregnation process, improve impregnation efficiency and simplify the procedure. Accordingly, an innovative experimental platform is presented that systematically investigates the effects of fiber bundle packing states, impregnation and preheating temperatures, speed, and pressure on the impregnation efficiency of single‑fiber bundles. Process decoupling, combined with fiber wettability and bundle morphology, reveals the correlation between fiber cross‑sectional morphological variations and the degree of impregnation. The quality of the composite filaments and printed parts is then assessed through mechanical tests coupled with microstructural analysis. The results indicate that sufficient impregnation time and higher temperatures can significantly improve the degree of impregnation. The effect of pressure strongly depends on the fiber bundle packing state. Pretreated, fully spread fiber bundles show a steadily increasing degree of impregnation with increasing pressure, reaching about three times that of the other two groups at the maximum pressure. Following the outcomes, we optimized the impregnation process and developed composite filament production equipment. 1 K Continuous carbon fiber reinforced nylon 6 composite filaments (1 K-CF/PA6) are successfully produced through a single-pass extrusion-pultrusion process at 260 mm/min, achieving a fiber volume fraction of 31.8% and average tensile strength of 1060.15 MPa. Printed parts exhibit an average flexural strength of 807.41 MPa, demonstrating the high quality of the produced composite filaments. These yield insights into the future development and process refinement of high-quality, cost-effective continuous fiber impregnation systems.
Keywords:
continuous carbon fiber
melting impregnation
fiber bundle packing
process optimization
composite filament
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