Future of High-Performance 3D Printing with Nylon Carbon Fiber: A Comprehensive Review

Authors

  • Nidhi Ahuja Nigam, Preeti Nitin Bhat, Sudhir Kumar

Keywords:

Additive Manufacturing; Nylon Carbon Fibre Composites; Fusion Deposition Modelling; Hybrid Manufacturing

Abstract

This comprehensive review examines the future of high-performance 3D printing with nylon carbon fiber composites, synthesizing recent advances in materials science, processing strategies, and application development. The study aimed to critically evaluate how matrix modification, fiber type and architecture, and fused deposition modelling parameters influence mechanical, thermal, and functional performance. The review assessed the effects of layer height, raster orientation, infill density, extrusion temperature, and post processing on anisotropy, strength, stiffness, fatigue resistance, and surface integrity. Findings showed that fiber orientation, interfacial bonding, and void control governed load transfer efficiency and reliability, while intelligent data driven models improved property prediction and reduced experimental burden. The analysis also identified persistent limitations, including process induced porosity, surface roughness, recyclability challenges, and variability in repeatability. The authors concluded that integrated process optimization, advanced reinforcement strategies, sustainable recycling pathways, and artificial intelligence assisted control are essential to achieve consistent structural performance and broader industrial adoption in aerospace, automotive, and smart manufacturing sectors. It guides future research priorities and industrial policy decisions

Downloads

Download data is not yet available.

References

Y. LUO, “REAL DIRECT DIGITAL MANUFACTURING TRANSFORMS ADDITIVE MANUFACTURING,” OSTI OAI (U.S. Department of Energy Office of Scientific and Technical Information) , Nov. 2021, Accessed: Mar. 2025. [Online]. Available: https://www.osti.gov/biblio/1877860

K. Kanishka and B. Acherjee, “Revolutionizing manufacturing: A comprehensive overview of additive manufacturing processes, materials, developments, and challenges,” Journal of Manufacturing Processes , vol. 107, p. 574, Nov. 2023, doi: 10.1016/j.jmapro.2023.10.024.

M. Srivastava, S. Rathee, V. Patel, A. Kumar, and P. G. Koppad, “A review of various materials for additive manufacturing: Recent trends and processing issues,” Journal of Materials Research and Technology , vol. 21. Elsevier BV, p. 2612, Oct. 18, 2022. doi: 10.1016/j.jmrt.2022.10.015.

H. A. Colorado, E. I. G. Velásquez, L. D. Gil, and Í. L. de Camargo, “Exploring the advantages and applications of nanocomposites produced via vat photopolymerization in additive manufacturing: A review,” Advanced Composites and Hybrid Materials , vol. 7, no. 1. Springer Science+Business Media, Dec. 20, 2023. doi: 10.1007/s42114-023-00808-z.

A. B. Shakir, F. A. R. Rozhbiany, and G. I. Khidhir, “Enhancing Mechanical Performance and Printing Efficiency of Nylon Reinforced by Carbon Fiber Using Fused Deposition Modeling: A Statistical Approach,” Journal of Materials Engineering and Performance , Dec. 2025, doi: 10.1007/s11665-025-12866-z.

G. M. Cheers et al. , “Influence of geometry, reinforcement, and sterilisation on the dimensional accuracy of additively manufactured carbon fibre-reinforced nylon composites,” Scientific Reports , vol. 15, no. 1, Oct. 2025, doi: 10.1038/s41598-025-16696-w.

K. Ramachandran, M. N. Azadani, P. Ravichandran, N. B. Shivaprakash, M. Obi, and C. L. Gnanasagaran, “Failure mechanics of fused filament fabricated nylon/carbon-reinforced composites,” Progress in Additive Manufacturing , vol. 9, no. 6, p. 2089, Feb. 2024, doi: 10.1007/s40964-024-00565-5.

A. K. Palaniappan, A. F. Sahayaraj, S. Rajesh, and U. Karthick, “Investigating the Parameters of Carbon Fiber Nylon Composites Using the Fused Deposition Modeling Process to Determine the Mechanical Characteristics and Properties of the Composites,” Journal of Materials Engineering and Performance , vol. 34, no. 19, p. 22795, Mar. 2025, doi: 10.1007/s11665-025-10928-w.

D. Dubey, S. P. Singh, and B. K. Behera, “Mechanical, thermal, and microstructural analysis of 3D printed short carbon fiber-reinforced nylon composites across diverse infill patterns,” Progress in Additive Manufacturing , vol. 10, no. 2, p. 1671, Jul. 2024, doi: 10.1007/s40964-024-00731-9.

M. Galati, P. Minetola, and G. Rizza, “Characterization and Finite Element Analyses of Tensile and Bending Behavior of Nylon Reinforced with Continuous Carbon Fiber Produced by Additive Manufacturing,” Journal of Materials Engineering and Performance , Sep. 2025, doi: 10.1007/s11665-025-11934-8.

B. Safaei et al. , “Challenges and Advancements in Additive Manufacturing of Nylon and Nylon Composite Materials: A Comprehensive Analysis of Mechanical Properties, Morphology, and Recent Progress,” Journal of Materials Engineering and Performance , vol. 33, no. 13, p. 6261, May 2024, doi: 10.1007/s11665-024-09368-9.

Y. Zhang et al. , “A review of 3D printing continuous carbon fiber reinforced thermoplastic polymers: Materials, processes, performance enhancement, and failure analysis,” Polymer Composites , vol. 46, no. 14. Wiley, p. 12619, Apr. 25, 2025. doi: 10.1002/pc.29895.

R. da S. Manca et al. , “Additive Manufacturing in Industry 4.0 and its Implications for Sustainability in Production Processes,” Revista de Gestão Social e Ambiental , vol. 18, no. 1, May 2024, doi: 10.24857/rgsa.v18n1-139.

S. K. Parupelli and S. Desai, “A Comprehensive Review of Additive Manufacturing (3D Printing): Processes, Applications and Future Potential,” American Journal of Applied Sciences , vol. 16, no. 8. Science Publications, p. 244, Aug. 01, 2019. doi: 10.3844/ajassp.2019.244.272.

R. Spina, L. Morfini, and L. M. Galantucci, “Mechanical properties of lightweight 3D-printed structures made with carbon-filled nylon,” Progress in Additive Manufacturing , vol. 9, no. 6, p. 2483, Apr. 2024, doi: 10.1007/s40964-024-00595-z.

N. Heathman, M. DeLay, and M. Tehrani, “Five-axis material extrusion of high-performance structural parts with continuous carbon fiber-reinforced LM-PAEK,” Research Square (Research Square) , Nov. 2024, doi: 10.21203/rs.3.rs-5412244/v1.

C. Burnett, G. Graninger, Z. Eren, B. G. Falzon, and Z. Kazancı, “Tensile performance of carbon fibre-reinforced 3D-printed polymers: Effect of printing parameters,” Engineering Failure Analysis , vol. 175, p. 109577, Apr. 2025, doi: 10.1016/j.engfailanal.2025.109577.

H. Gonabadi, A. Yadav, and S. J. Bull, “The effect of processing parameters on the mechanical characteristics of PLA produced by a 3D FFF printer,” The International Journal of Advanced Manufacturing Technology , vol. 111, p. 695, Oct. 2020, doi: 10.1007/s00170-020-06138-4.

J. Brackett et al. , “CHARACTERIZING THE INFLUENCE OF PRINT PARAMETERS ON POROSITY AND RESULTING DENSITY,” OSTI OAI (U.S. Department of Energy Office of Scientific and Technical Information) , Nov. 2019, Accessed: Sep. 2025. [Online]. Available: https://www.osti.gov/biblio/1831705

Bianchi, T. Mancia, C. Mignanelli, and M. Simoncini, “Effect of nozzle wear on mechanical properties of 3D printed carbon fiber-reinforced polymer parts by material extrusion,” The International Journal of Advanced Manufacturing Technology , vol. 130, p. 4699, Jan. 2024, doi: 10.1007/s00170-024-13035-7.

N. G. Abetu, “Review on Comparison of Composite Material Preparation: Traditional vs. Modern Methods and the Future Paradigm Shift,” International Journal for Research in Applied Science and Engineering Technology , vol. 13, no. 5, p. 6946, May 2025, doi: 10.22214/ijraset.2025.71779.

S. Kumari, P. Vishwakarma, and K. Abhishek, “Advancements in 3D Printing Materials for Diverse Industries: A Review and Future Prospects,” E3S Web of Conferences , vol. 552. EDP Sciences, p. 1038, Jan. 01, 2024. doi: 10.1051/e3sconf/202455201038.

M. T. H. Sarker and M. A. Rahaman, “ADVANCEMENTS IN 3D PRINTING TECHNIQUES FOR POLYMER FIBER-REINFORCED TEXTILE COMPOSITES: A SYSTEMATIC LITERATURE REVIEW,” American Journal of Interdisciplinary Studies , vol. 3, no. 4, p. 32, Dec. 2022, doi: 10.63125/s4r5m391.

Y. Jiang, A. X. Serrano, W. Choi, R. C. Advíncula, and H. F. Wu, “Advanced and functional composite materials via additive manufacturing: Trends and perspectives,” MRS Communications , vol. 14, no. 4, p. 449, Aug. 2024, doi: 10.1557/s43579-024-00625-5.

M. M. Rahman et al. , “Polymer Composites in Additive Manufacturing: Current Technologies, Applications, and Emerging Trends,” Polymers , vol. 18, no. 2, p. 192, Jan. 2026, doi: 10.3390/polym18020192.

N. Gupta, C. P. Antham, K. K. Das, R. Goel, R. S. Zabibah, and M. Kumar, “Advanced Composite Manufacturing using Additive Manufacturing and Robotic Techniques,” E3S Web of Conferences , vol. 430, p. 1118, Jan. 2023, doi: 10.1051/e3sconf/202343001118.

Yu, M. L. Dunn, H. J. Qi, and K. Maute, “Recent advances in design optimization and additive manufacturing of composites: from enhanced mechanical properties to innovative functionalities,” npj Advanced Manufacturing , vol. 2, no. 1, Jun. 2025, doi: 10.1038/s44334-025-00040-1.

T. Liu, S. Lu, M. Wang, H. Wang, and Z. Zhao, “Type of the Paper: Article,” SSRN Electronic Journal , Jan. 2024, doi: 10.2139/ssrn.4950065.

A. Kantaros, E. D. Soulis, F. I. T. Petrescu, and T. Ganetsos, “Advanced Composite Materials Utilized in FDM/FFF 3D Printing Manufacturing Processes: The Case of Filled Filaments,” Materials , vol. 16, no. 18, p. 6210, Sep. 2023, doi: 10.3390/ma16186210.

M. Mohammadizadeh and I. Fidan, “Tensile Performance of 3D-Printed Continuous Fiber-Reinforced Nylon Composites,” Journal of Manufacturing and Materials Processing , vol. 5, no. 3, p. 68, Jun. 2021, doi: 10.3390/jmmp5030068.

N. A. Zulkefli et al. , “Hybrid nanofiller reinforcement in thermoset and biothermoset applications: A review,” Nanotechnology Reviews , vol. 12, no. 1. De Gruyter, Jan. 01, 2023. doi: 10.1515/ntrev-2022-0499.

B. H. Dhage and N. Khedkar, “Predictive machine learning and printing parameter optimization for enhanced impact performance of 3D-printed Onyx-Kevlar composites,” Discover Materials , vol. 5, no. 1, Aug. 2025, doi: 10.1007/s43939-025-00307-6.

Opalach, J. Porter-Sobieraj, and P. Zdroik, “Stacking optimization of 3D printed continuous fiber layer designs,” Advances in Engineering Software , vol. 164, p. 103077, Dec. 2021, doi: 10.1016/j.advengsoft.2021.103077.

Z. Tian, G. C.-P. Tsui, Y. M. Tang, C. H. Wong, C. Y. Tang, and C. Ko, “Additive Manufacturing for Nanogenerators: Fundamental Mechanisms, Recent Advancements, and Future Prospects,” Nano-Micro Letters , vol. 18, no. 1. Springer Science+Business Media, Aug. 11, 2025. doi: 10.1007/s40820-025-01874-2.

S. Dul, L. Fambri, and A. Pegoretti, “High-Performance Polyamide/Carbon Fiber Composites for Fused Filament Fabrication: Mechanical and Functional Performances,” Journal of Materials Engineering and Performance , vol. 30, no. 7, p. 5066, Apr. 2021, doi: 10.1007/s11665-021-05635-1.

H. R. Vanaei, A. E. Magri, M. A. Rastak, S. Vanaei, S. Vaudreuil, and A. Tcharkhtchi, “Numerical–Experimental Analysis toward the Strain Rate Sensitivity of 3D-Printed Nylon Reinforced by Short Carbon Fiber,” Materials , vol. 15, no. 24, p. 8722, Dec. 2022, doi: 10.3390/ma15248722.

Yu and M. L. Dunn, “Design and Extrusion-Based 3D Printing of Continuous Fiber Composites: Status, Challenges, and Opportunities,” Langmuir , vol. 40, no. 17, p. 8751, Apr. 2024, doi: 10.1021/acs.langmuir.4c00139.

Sadeghzade, A. Dadashi, and H. Gharehbaghi, “Mechanical behavior, process innovations, and future directions of 3d-printed continuous fiber-reinforced polymeric lattice structures: A comprehensive review,” Materials & Design , vol. 260. Elsevier BV, p. 114970, Oct. 31, 2025. doi: 10.1016/j.matdes.2025.114970.

Y. Delporte and H. Ghasemnejad, “Manufacturing of 3D Printed Laminated Carbon Fibre Reinforced Nylon Composites: Impact Mechanics,” Open Journal of Composite Materials , vol. 11, no. 1, p. 1, Jan. 2021, doi: 10.4236/ojcm.2021.111001.

T. Fisher, J. H. S. Almeida, B. G. Falzon, and Z. Kazancı, “Tension and Compression Properties of 3D-Printed Composites: Print Orientation and Strain Rate Effects,” Polymers , vol. 15, no. 7, p. 1708, Mar. 2023, doi: 10.3390/polym15071708.

A. M. Radzuan, N. N. Khalid, F. M. Foudzi, N. R. R. Royan, and A. B. Sulong, “Mechanical Analysis of 3D Printed Polyamide Composites under Different Filler Loadings,” Polymers , vol. 15, no. 8, p. 1846, Apr. 2023, doi: 10.3390/polym15081846.

A. A. Rashid, H. IKRAM, and M. Koç‬, “Effect of carbon fiber reinforcement on dimensional variations of 3D printed polyamide-6 composites: A simulation study,” TURKISH JOURNAL OF CHEMISTRY , vol. 47, no. 1, p. 33, Jan. 2023, doi: 10.55730/1300-0527.3513.

M. Ahmadifar, K. Benfriha, M. Shirinbayan, and A. Tcharkhtchi, “Additive Manufacturing of Polymer-Based Composites Using Fused Filament Fabrication (FFF): a Review,” Applied Composite Materials , vol. 28, no. 5. Springer Science+Business Media, p. 1335, Aug. 02, 2021. doi: 10.1007/s10443-021-09933-8.

M. Alarifi, “A performance evaluation study of 3d printed nylon/glass fiber and nylon/carbon fiber composite materials,” Journal of Materials Research and Technology , vol. 21, p. 884, Sep. 2022, doi: 10.1016/j.jmrt.2022.09.085.

Z. Zhang, C. Hu, and Q. Qin, “The improvement of void and interface characteristics in fused filament fabrication-based polymers and continuous carbon fiber-reinforced polymer composites: a comprehensive review,” The International Journal of Advanced Manufacturing Technology , vol. 137. Springer Science+Business Media, p. 1047, Feb. 21, 2025. doi: 10.1007/s00170-025-15240-4.

M. Mohammadizadeh, A. Gupta, and I. Fidan, “Mechanical benchmarking of additively manufactured continuous and short carbon fiber reinforced nylon,” Journal of Composite Materials , vol. 55, no. 25, p. 3629, May 2021, doi: 10.1177/00219983211020070.

A. Uşun, R. Gümrük, N. YILDIZ, and B. B. Vatandaş, “EXAMINATION OF THE INFLUENCE OF PRINTING PARAMETERS FOR THE CONTINUOUS CARBON FIBER-REINFORCED THERMOPLASTICS BASED ON FUSED DEPOSITION MODELING,” DergiPark (Istanbul University) , Nov. 2021, Accessed: Oct. 2025. [Online]. Available: https://dergipark.org.tr/tr/pub/tijmet/issue/72047/899728

M. Placci, L. Bernini, P. Albertelli, C. Cimino, F. Perotti, and M. Monno, “A Review on Circular Economy Approaches for Pre-impregnated Carbon Composites Mould Remanufacturing,” International Journal of Precision Engineering and Manufacturing-Green Technology . Springer Science+Business Media, Sep. 08, 2025. doi: 10.1007/s40684-025-00776-3.

F. B. Kilinc, T. Türkoğlu, S. Güler, and A. Ç. Kılınç, “Optimization of 3D printing parameters for enhanced tensile properties in continuous carbon fiber reinforced PLA composites,” Materials Research Express , vol. 12, no. 4, p. 45302, Mar. 2025, doi: 10.1088/2053-1591/adc5cc.

E. Kargar and A. Ghasemi‐Ghalebahman, “Experimental investigation on fatigue life and tensile strength of carbon fiber-reinforced PLA composites based on fused deposition modeling,” Scientific Reports , vol. 13, no. 1, Oct. 2023, doi: 10.1038/s41598-023-45046-x.

A. A. Ansari and M. Kamil, “Performance Study of 3D Printed Continuous Fiber-Reinforced Polymer Composites Using Taguchi Method,” Journal of Materials Engineering and Performance , vol. 32, no. 21, p. 9892, Dec. 2022, doi: 10.1007/s11665-022-07715-2.

E. Azizian-Farsani, M. R. Moghanlou, A. Mahmoudi, P. J. Wilson, and M. M. Khonsari, “On the optimization of fatigue limit in additively manufactured fiber reinforced polymer composites,” Progress in Additive Manufacturing , vol. 10, no. 9, p. 6131, Jan. 2025, doi: 10.1007/s40964-025-00961-5.

L. Beníček, M. Vašina, and P. Hrbáček, “Influence of 3D Printing Conditions on Physical–Mechanical Properties of Polymer Materials,” Polymers , vol. 17, no. 1, p. 43, Dec. 2024, doi: 10.3390/polym17010043.

T. J. Scott, T. J. Beaulieu, G. D. Rothrock, and A. C. O’Connor, “Economic Analysis of Technology Infrastructure Needs for Advanced Manufacturing: Additive Manufacturing,” Oct. 2016. doi: 10.6028/nist.gcr.16-006.

F. Mashayekhi, J. Bardon, V. Berthé, H. Perrin, S. Westermann, and F. Addiego, “Fused Filament Fabrication of Polymers and Continuous Fiber-Reinforced Polymer Composites: Advances in Structure Optimization and Health Monitoring,” Polymers , vol. 13, no. 5. Multidisciplinary Digital Publishing Institute, p. 789, Mar. 04, 2021. doi: 10.3390/polym13050789.

S. V. Kuchampudi, K. L. Meena, and R. B. R. Chekuri, “An experimental investigation on 3d printing of PETG-KF-based composites: optimization of process parameters for improved mechanical properties,” Cogent Engineering , vol. 11, no. 1, Jul. 2024, doi: 10.1080/23311916.2024.2379989.

M. Sabet, “Revolutionizing structures: the rise of high-performance composite and nanocomposite polymers,” Polymer Bulletin , vol. 82, no. 10, p. 4257, Mar. 2025, doi: 10.1007/s00289-025-05720-8.

A. Moreno‐Núñez, C. G. Abarca-Vidal, C. D. Treviño‐Quintanilla, U. Sánchez-Santana, E. Cuan‐Urquizo, and E. Uribe-Lam, “Experimental Analysis of Fiber Reinforcement Rings’ Effect on Tensile and Flexural Properties of Onyx TM –Kevlar® Composites Manufactured by Continuous Fiber Reinforcement,” Polymers , vol. 15, no. 5, p. 1252, Mar. 2023, doi: 10.3390/polym15051252.

W. L. Ng, J. An, and C. K. Chua, “Process, Material, and Regulatory Considerations for 3D Printed Medical Devices and Tissue Constructs,” Engineering , vol. 36, p. 146, Apr. 2024, doi: 10.1016/j.eng.2024.01.028.

M. Klossa, N. Chatzidai, and D. Karalekas, “Tensile properties of 3D printed carbon fiber reinforced nylon specimens,” Materials Today Proceedings , vol. 93, p. 571, Jan. 2023, doi: 10.1016/j.matpr.2023.02.107.

A. P. Marzuki et al. , “Fabrication and evaluation of PLA/PA-HA filament for 3D printing: towards trabecular bone-compatible biomedical applications,” The International Journal of Advanced Manufacturing Technology , Oct. 2025, doi: 10.1007/s00170-025-16623-3.

G. Paul et al. , “Medical Applications for 3D Printing: Recent Developments.,” PubMed , vol. 115, no. 1, p. 75, Aug. 2019, Accessed: Nov. 2025. [Online]. Available: https://pubmed.ncbi.nlm.nih.gov/30228688

A. B. Singh, “Transforming Healthcare: A Review of Additive Manufacturing Applications in the Healthcare Sector.” p. 2, Sep. 10, 2024. doi: 10.3390/engproc2024072002.

F. Egan, V. C. Gonella, M. Engensperger, S. J. Ferguson, and K. Shea, “Computationally designed lattices with tuned properties for tissue engineering using 3D printing,” PLoS ONE , vol. 12, no. 8, Aug. 2017, doi: 10.1371/journal.pone.0182902.

Pathak et al. , “3D printing in biomedicine: advancing personalized care through additive manufacturing,” Exploration of Medicine , p. 1135, Dec. 2023, doi: 10.37349/emed.2023.00200.

M. Shakiba et al. , “Nylon—A material introduction and overview for biomedical applications,” Polymers for Advanced Technologies , vol. 32, no. 9, p. 3368, May 2021, doi: 10.1002/pat.5372.

Mayandi et al. , “Effects of infill density on mechanical properties of additively manufactured chopped carbon fiber reinforced PLA composites,” Materials Science-Poland , vol. 42, no. 1, p. 42, Mar. 2024, doi: 10.2478/msp-2024-0003.

S. Hartomacıoğlu, “Optimization of Production Parameters for Impact Strength of 3D-Printed Carbon/Glass Fiber-Reinforced Nylon Composite in Critical ZX Printing Orientation,” Polymers , vol. 16, no. 21, p. 3006, Oct. 2024, doi: 10.3390/polym16213006.

M. Alarifi, “PETG/carbon fiber composites with different structures produced by 3D printing,” Polymer Testing , vol. 120, p. 107949, Feb. 2023, doi: 10.1016/j.polymertesting.2023.107949.

S. Simões, “High-Performance Advanced Composites in Multifunctional Material Design: State of the Art, Challenges, and Future Directions,” Materials , vol. 17, no. 23. Multidisciplinary Digital Publishing Institute, p. 5997, Dec. 07, 2024. doi: 10.3390/ma17235997.

Pizzorni, A. Parmiggiani, and M. Prato, “Adhesive bonding of a mixed short and continuous carbon-fiber-reinforced Nylon-6 composite made via fused filament fabrication,” International Journal of Adhesion and Adhesives , vol. 107, p. 102856, Mar. 2021, doi: 10.1016/j.ijadhadh.2021.102856.

R. R. Fernandes, A. Y. Tamijani, and M. Al‐Haik, “Mechanical characterization of additively manufactured fiber-reinforced composites,” Aerospace Science and Technology , vol. 113, p. 106653, Mar. 2021, doi: 10.1016/j.ast.2021.106653.

A. Pandžić, E. Kadrić, and S. Kolesar, “Investigating the Influence of Printing Orientation and Filament Drying on Tensile and Flexural Strength of FDM-Printed Carbon Fiber-Reinforced Polyamide Composites,” in Annals of DAAAM for ... & proceedings of the ... International DAAAM Symposium , DAAAM International Vienna, 2023, p. 146. doi: 10.2507/34th.daaam.proceedings.020.

Muhamedagić and A. Çekiç, “Optimization FDM Process Parameters for Flexural Strength Improvement of Carbon Fibers Reinforcered Polyamide Parts,” in Annals of DAAAM for ... & proceedings of the ... International DAAAM Symposium , DAAAM International Vienna, 2022, p. 262. doi: 10.2507/33rd.daaam.proceedings.036.

Kaya, Ş. Demiç, and M. Karaman, “Fabrication of Carbon Fiber/Silicon Carbide Hybride Polypropylene Composites as Thermal Interface Material,” Polymer Science Series A , vol. 66, no. 4, p. 582, Aug. 2024, doi: 10.1134/s0965545x2460128x.

Jung, E. J. Shin, and S. Lee, “Study on CNT/TPU cube under the 3D printing conditions of infill patterns and density,” Scientific Reports , vol. 13, no. 1, Oct. 2023, doi: 10.1038/s41598-023-44951-5.

Tanks and K. Tamura, “Room‐Temperature Material Recycling/Upcycling of Polyamide Waste Enabled by Cosolvent‐Tunable Dissolution Kinetics,” Angewandte Chemie International Edition , vol. 64, no. 31, May 2025, doi: 10.1002/anie.202502474.

Zheng et al. , “Chemical Recycling of Carbon Fiber-Reinforced Nylon Composites,” ACS Materials Letters , Feb. 2026, doi: 10.1021/acsmaterialslett.5c01543.

H. Zhang et al. , “Degradation of Carbon Fiber-Reinforced Polymer Composites in Salt Water and Rapid Evaluation by Electrochemical Impedance Spectroscopy,” Materials , vol. 16, no. 4, p. 1676, Feb. 2023, doi: 10.3390/ma16041676.

Ahmadifar, K. Benfriha, and M. Shirinbayan, “Thermal, Tensile and Fatigue Behaviors of the PA6, Short Carbon Fiber-Reinforced PA6, and Continuous Glass Fiber-Reinforced PA6 Materials in Fused Filament Fabrication (FFF),” Polymers , vol. 15, no. 3, p. 507, Jan. 2023, doi: 10.3390/polym15030507.

Y. Hou and A. Panesar, “The moisture absorption of additively manufactured short carbon fibre reinforced polyamide,” Composites Part A Applied Science and Manufacturing , vol. 188, p. 108528, Oct. 2024, doi: 10.1016/j.compositesa.2024.108528.

A. K. Sambale, M. Stanko, J. Emde, and M. Stommel, “Characterisation and FE Modelling of the Sorption and Swelling Behaviour of Polyamide 6 in Water,” Polymers , vol. 13, no. 9, p. 1480, May 2021, doi: 10.3390/polym13091480.

S. Montagna, G. F. de M. Morgado, A. Guimarães, F. R. Passador, and M. C. Rezende, “Fractographic Study of Thermoplastic Composites Based on Carbon Fiber/PA6 Conditioned in Heated Distilled Water and Saline Solution and Tested in Tensile,” Research Square (Research Square) , Aug. 2023, doi: 10.21203/rs.3.rs-3282376/v1.

Majko, M. Vaško, M. Handrik, and M. Sága, “Challenges in Tensile Testing of Thermoplastic Composites Reinforced with Chopped Carbon Fibre Produced by Fused Filament Fabrication Method,” MANUFACTURING TECHNOLOGY , vol. 23, no. 2, p. 216, Apr. 2023, doi: 10.21062/mft.2023.010.

Nikiema, P. Balland, and A. Sergent, “Study of the Mechanical Properties of 3D-Printed Onyx Parts: Investigation on Printing Parameters and Effect of Humidity,” SSRN Electronic Journal , Jan. 2023, doi: 10.2139/ssrn.4440863.

Ghabezi, T. Flanagan, M. Walls, and N. M. Harrison, “Degradation characteristics of 3D printed continuous fibre-reinforced PA6/chopped fibre composites in simulated saltwater,” Progress in Additive Manufacturing , vol. 10, no. 1, p. 725, May 2024, doi: 10.1007/s40964-024-00654-5.

J. P. Lewicki et al. , “3D-Printing of Meso-structurally Ordered Carbon Fiber/Polymer Composites with Unprecedented Orthotropic Physical Properties,” Scientific Reports , vol. 7, no. 1, Mar. 2017, doi: 10.1038/srep43401.

C. E. Bakis, R. T. Haluza, J. Bartolai, J. J. Kim, and T. W. Simpson, “Assessment of anisotropic mechanical properties of a 3D printed carbon whisker reinforced composite,” Advanced Composite Materials , vol. 28, no. 5, p. 545, Aug. 2019, doi: 10.1080/09243046.2019.1652030.

Hedjazi, S. Belhabib, N. Stéphant, S. Durand, and S. Guessasma, “Effects of Microstructural Arrangement on the Mechanical Behavior of 3D Printed Polyamide,” Symmetry , vol. 15, no. 12, p. 2119, Nov. 2023, doi: 10.3390/sym15122119.

A. Economides, M. N. Islam, and K. P. Baxevanakis, “Additively Manufactured Carbon Fibre PETG Composites: Effect of Print Parameters on Mechanical Properties,” Polymers , vol. 16, no. 23, p. 3336, Nov. 2024, doi: 10.3390/polym16233336.

Touchard, L. Chocinski‐Arnault, T. Fournier, C. Magro, A. Lafitte, and A. Caradec, “Interfacial adhesion quality in 3D printed continuous CF/PA6 composites at filament/matrix and interlaminar scales,” Composites Part B Engineering , vol. 218, p. 108891, Apr. 2021, doi: 10.1016/j.compositesb.2021.108891.

Zhilyaev et al. , “Experimental and numerical analysis of the consolidation process for additive manufactured continuous carbon fiber-reinforced polyamide 12 composites,” Frontiers in Materials , vol. 9, Dec. 2022, doi: 10.3389/fmats.2022.1068261.

Bandinelli, M. Scapin, and L. Peroni, “Effects of anisotropy and infill pattern on compression properties of 3D printed CFRP: mechanical analysis and elasto-plastic finite element modelling,” Rapid Prototyping Journal , vol. 30, no. 11, p. 142, Jun. 2024, doi: 10.1108/rpj-11-2023-0385.

Wu, Z. Ka, and D. Yang, “Material extrusion additive manufacturing of recycled discontinuous carbon fibre reinforced thermoplastic composites with different fibre lengths: Through-process microstructural evolution and mechanical property loss,” Additive manufacturing , vol. 78, p. 103839, Sep. 2023, doi: 10.1016/j.addma.2023.103839.

Wu, Z. Ka, and dongmin yang, “Material Extrusion Additive Manufacturing of Recycled Discontinuous Carbon Fibre Reinforced Thermoplastic Composites with Different Fibre Lengths: Through-Process Microstructural Evolution and Mechanical Property Loss,” Jan. 2023, doi: 10.2139/ssrn.4423086.

Batley, R. Glithro, B. Dyer, and P. Sewell, “Evaluation of Tensile Strength and Repeatability of 3D Printed Carbon Fiber Materials and Processes,” 3D Printing and Additive Manufacturing , vol. 11, no. 5, p. 1691, Oct. 2023, doi: 10.1089/3dp.2022.0262.

Zhang et al. , “Microwave radiation-induced interfacial gradient effect of 3D printing CF/PA12 composite for enhancing mechanical performance,” Research Square (Research Square) , Oct. 2023, doi: 10.21203/rs.3.rs-3429483/v1.

Zhuo, S. Li, I. Ashcroft, and A. I. Jones, “Material extrusion additive manufacturing of continuous fibre reinforced polymer matrix composites: A review and outlook,” Composites Part B Engineering , vol. 224. Elsevier BV, p. 109143, Jul. 18, 2021. doi: 10.1016/j.compositesb.2021.109143.

N. Khalid, N. A. M. Radzuan, A. B. Sulong, F. M. Foudzi, and A. Hasran, “Rheological Test of Flowability and Diffusion Behavior of Carbon Fibre Reinforced Polyamide,” Jurnal Kejuruteraan , vol. 35, no. 1, p. 215, Jan. 2023, doi: 10.17576/jkukm-2023-35(1)-20.

A. M. Radzuan, A. B. Sulong, A. Verma, and N. Muhamad, “Layup sequence and interfacial bonding of additively manufactured polymeric composite: A brief review,” Nanotechnology Reviews , vol. 10, no. 1. De Gruyter, p. 1853, Jan. 01, 2021. doi: 10.1515/ntrev-2021-0116.

X. Li, “Multiscale computational modeling of 3D printed continuous Fiber reinforced polymer composites,” Scientific Reports , vol. 15, no. 1, May 2025, doi: 10.1038/s41598-025-01556-4.

M. Hernandez, S. C. O’Brien, A. Bischoff, J. P. Parmigiani, and D. J. Roach, “Influence of 3D printing parameters on ULTEM 9085 mechanical properties using experimentation and machine learning,” npj Advanced Manufacturing , vol. 2, no. 1, Sep. 2025, doi: 10.1038/s44334-025-00049-6.

Shen, Y. Guo, Z. Shen, F. Yan, and N. Zhong, “Additive Manufacturing of Aerospace Composites: A Critical Review of the Material–Process–Design Interplay and Prospects for Application,” Materials , vol. 18, no. 18. Multidisciplinary Digital Publishing Institute, p. 4280, Sep. 12, 2025. doi: 10.3390/ma18184280.

V. Candela et al. , “Smoothening of the down-skin regions of copper components produced via Laser Powder Bed Fusion technology,” The International Journal of Advanced Manufacturing Technology , vol. 123, p. 3205, Nov. 2022, doi: 10.1007/s00170-022-10408-8.

Gallinaro, “Additive Manufacturing-Based Supply Chain Configurations,” in IntechOpen eBooks , IntechOpen, 2023. doi: 10.5772/intechopen.110174.

J. Lettori, R. Raffaeli, M. Peruzzini, J. Schmidt, and M. Pellicciari, “Additive manufacturing adoption in product design: an overview from literature and industry,” Procedia Manufacturing , vol. 51, p. 655, Jan. 2020, doi: 10.1016/j.promfg.2020.10.092.

Q. Fan, H. Duan, and X. Xing, “A review of composite materials for enhancing support, flexibility and strength in exercise,” Alexandria Engineering Journal , vol. 94, p. 90, Mar. 2024, doi: 10.1016/j.aej.2024.03.048.

Ye, C. Zhang, J. Zhao, and Y. Dong, “Effects of Post-processing on the Surface Finish, Porosity, Residual Stresses, and Fatigue Performance of Additive Manufactured Metals: A Review,” Journal of Materials Engineering and Performance , vol. 30, no. 9. Springer Science+Business Media, p. 6407, Jul. 26, 2021. doi: 10.1007/s11665-021-06021-7.

Shishkovsky, Advanced Additive Manufacturing . IntechOpen, 2021. doi: 10.5772/intechopen.95667.

A. Sola and A. Trinchi, “Recycling as a Key Enabler for Sustainable Additive Manufacturing of Polymer Composites: A Critical Perspective on Fused Filament Fabrication,” Polymers , vol. 15, no. 21. Multidisciplinary Digital Publishing Institute, p. 4219, Oct. 25, 2023. doi: 10.3390/polym15214219.

Sola, “Materials Requirements in Fused Filament Fabrication: A Framework for the Design of Next‐Generation 3D Printable Thermoplastics and Composites,” Macromolecular Materials and Engineering , vol. 307, no. 10, Oct. 2022, doi: 10.1002/mame.202270042.

Wagmare, R. Harshe, J. Pednekar, and T. U. Patro, “Additive manufacturing of continuous fiber-reinforced polymer composites: current trend and future directions,” Progress in Additive Manufacturing , vol. 10, no. 4, p. 1973, Sep. 2024, doi: 10.1007/s40964-024-00777-9.

Li, K. Wang, W. Zhu, Y. Peng, S. Ahzi, and F. Chinesta, “Investigation on the mechanical properties of 3D printed hybrid continuous fiber-filled composite considering influence of interfaces,” The International Journal of Advanced Manufacturing Technology , vol. 123, p. 3147, Nov. 2022, doi: 10.1007/s00170-022-10398-7.

S. Li et al. , “Advances in hybrid fibers reinforced polymer-based composites prepared by FDM: A review on mechanical properties and prospects,” Composites Communications , vol. 40. Elsevier BV, p. 101592, Apr. 15, 2023. doi: 10.1016/j.coco.2023.101592.

Gupta, G. Srilekha, K. K. Das, R. Goel, M. S. Mashkour, and M. Kumar, “Novel Manufacturing Techniques for Multifunctional Composites: Integration of Sensors and Actuators,” E3S Web of Conferences , vol. 430, p. 1117, Jan. 2023, doi: 10.1051/e3sconf/202343001117.

S. S. Kumar, J. S. Akmal, and M. Salmi, “4D printing of shape memory polymer with continuous carbon fiber,” Progress in Additive Manufacturing , vol. 9, no. 6, p. 1985, Dec. 2023, doi: 10.1007/s40964-023-00553-1.

A. C. Et.al, “Current Advances In The Nanofiber (NF) Based Polymer Composites,” Türk bilgisayar ve matematik eğitimi dergisi , vol. 12, no. 6, p. 7, Apr. 2021, doi: 10.17762/turcomat.v12i6.1249.

A. Nafi and M. P. Jahan, “Functional Surface Generation by EDM—A Review,” Micromachines , vol. 14, no. 1. Multidisciplinary Digital Publishing Institute, p. 115, Dec. 31, 2022. doi: 10.3390/mi14010115.

Hassan, M. Misra, G. W. Taylor, and A. K. Mohanty, “A review of AI for optimization of 3D printing of sustainable polymers and composites,” Composites Part C Open Access , vol. 15. Elsevier BV, p. 100513, Sep. 28, 2024. doi: 10.1016/j.jcomc.2024.100513.

S. Palanisamy et al. , “Machine learning approaches to natural fiber composites: A review of methodologies and applications,” BioResources , vol. 20, no. 1. North Carolina State University, Jan. 03, 2025. doi: 10.15376/biores.20.1.palanisamy.

Y. Chen, S. Hu, A. Li, Y. Cao, Y. Zhao, and W. Ming, “Parameters Optimization of Electrical Discharge Machining Process Using Swarm Intelligence: A Review,” Metals , vol. 13, no. 5. Multidisciplinary Digital Publishing Institute, p. 839, Apr. 24, 2023. doi: 10.3390/met13050839.

S. K. Lodhi, A. Y. Gill, and I. Hussain, “3D Printing Techniques: Transforming Manufacturing with Precision and Sustainability,” International Journal of Multidisciplinary Sciences and Arts , vol. 3, no. 3, p. 129, Aug. 2024, doi: 10.47709/ijmdsa.v3i3.4568.

A. Doğan and D. Birant, “Machine learning and data mining in manufacturing,” Expert Systems with Applications, vol. 166, p. 114060, Mar. 2021, doi: 10.1016/j.eswa.2020.114060

Downloads

Published

19.10.2024

How to Cite

Nidhi Ahuja Nigam. (2024). Future of High-Performance 3D Printing with Nylon Carbon Fiber: A Comprehensive Review. International Journal of Intelligent Systems and Applications in Engineering, 12(21s), 5236–5260. Retrieved from https://www.ijisae.org/index.php/IJISAE/article/view/8073

Issue

Vol. 12 No. 21s (2024)

Section

Research Article

License

Creative Commons License

This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.

All papers should be submitted electronically. All submitted manuscripts must be original work that is not under submission at another journal or under consideration for publication in another form, such as a monograph or chapter of a book. Authors of submitted papers are obligated not to submit their paper for publication elsewhere until an editorial decision is rendered on their submission. Further, authors of accepted papers are prohibited from publishing the results in other publications that appear before the paper is published in the Journal unless they receive approval for doing so from the Editor-In-Chief.

IJISAE open access articles are licensed under a Creative Commons Attribution-ShareAlike 4.0 International License. This license lets the audience to give appropriate credit, provide a link to the license, and indicate if changes were made and if they remix, transform, or build upon the material, they must distribute contributions under the same license as the original.