International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278

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Review

An insight into additive manufacturing of fiber reinforced polymer

composite
Divya Zindani a, Kaushik Kumar b, *
a
Department of Mechanical Engineering, National Institute of Technology Silchar, Silchar, India
b
Department of Mechanical Engineering, Birla Institute of Technology Mesra, Ranchi, India

a r t i c l e i n f o a b s t r a c t

Article history: Production of complex products is achievable easily with the employability of additive manufacturing
Received 27 May 2019 technology. Customized products can be produced in mass through the usage of additive manufacturing
Received in revised form processes. Owing to the versatile feature, additive manufacturing has been employed in a variety of
28 July 2019
applications such as automotive, aerospace, biomedical, etc. additive manufacturing has gained special
Accepted 15 August 2019
Available online 20 August 2019
attraction due to its capability and potentiality to improve and modify the properties of materials
through the inclusion of reinforcements. The present work provides an overview of additive
manufacturing used in the manufacturing of fiber-reinforced polymeric composite materials. The scope
Keywords:
Additive manufacturing
of the work delineates different additive manufacturing processes, formulations of different materials,
Lightweight structures drawbacks, and strengths associated with different additive manufacturing processes. Fabrication of fiber
Polymeric composite reinforced polymeric composites remains the protagonist of the entire work. The challenges related to
Fiber reinforced the employability of additive manufacturing technologies in the fabrication of fiber reinforced polymeric
Vat photopolymerization composites are also highlighted towards the end of the work.
Liquid deposition modeling © 2019 The Authors. Production and hosting by Elsevier B.V. on behalf of KeAi Communications Co., Ltd.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-
nc-nd/4.0/).

1. Introduction polymeric composite materials economically and with greater

Polymeric composites with fibers as reinforcement have gained
the attention of researchers as well as industrialists. These com-
posite materials have high strength to weight ratio and therefore
landed themselves for a wide range of applications: automotive,
sports, construction etc. various manufacturing techniques have
been adopted to manufacture fiber reinforced polymeric composite
materials: pultrusion [1], filament winding [2], automated fiber
placement [3], automated tape laying [4], spray-up [5], resin
transfer molding [6,7]and manual layup [8]. However, the afore-
mentioned conventional techniques require the usage of molds and
thereby making them expensive. Furthermore, the formability of
the final part is also restricted because of the final part. Hence, it is
tedious as well as costly to produce complex and customized parts.
Additive manufacturing has arisen as a solution to the above
mentioned challenges and it is now possible to produce the
* Corresponding author.
E-mail address: kkumar@bitmesra.ac.in (K. Kumar).
Peer review under responsibility of Editorial Board of International Journal of
Lightweight Materials and Manufacture.
flexibility [9]. Additive manufacturing entails the production of
products through layer-by-layer process aided by a computer-aided
design file. As the mold requirement is eradicated in the additive
manufacturing process, it has become the cynosure of design in-
dustries. Functionally graded structures can be fabricated using an
additive manufacturing process as it boosts for flexibility in terms
of changing volume fraction and fiber orientation. As a result, ad-
ditive manufacturing has become one of the leading manufacturing
technologies for composite producing industries. Short fiber rein-
forced polymeric composites have been prepared for decades using
the additive manufacturing processes. Recent research energies
have been focused on the development of polymeric composites
with continuous fibers using additive manufacturing technologies
and in development of novel additive manufacturing processes that
can allow for the fabrication of parts possessing enhanced me-
chanical properties.
Some of the major requirements that are needed to be met in
order to process fiber reinforced polymeric composites using ad-
ditive manufacturing process involve: fiber alignment, minimal
porosity, types of reinforcement, types of matrices, good fiber-to-

https://doi.org/10.1016/j.ijlmm.2019.08.004
2588-8404/© 2019 The Authors. Production and hosting by Elsevier B.V. on behalf of KeAi Communications Co., Ltd. This is an open access article under the CC BY-NC-ND
license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
268 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278
matrix bonding and better bonding between different layers of the
composite specimen under fabrication.
Appropriateness pertaining to size, length, and shape of the fi-
ber to be reinforced needs to be justified in accordance with the
requirements. The matrix as well as reinforcing fibers must be
compatible with the technique of additive manufacturing process
to be used. Composite following the rule of the mixture will result
only if there is good bonding between the fiber and the matrix and
hence loads from the matrix can be transferred efficiently. Fiber
loading is another important factor that is critical to obtain com-
posites from additive manufacturing techniques. Consistent prop-
erties throughout the 3D printed composite can be ensured with
homogeneous fiber distribution of fibers within the matrix. The
desired sections of an object can be strengthened with the
controlled fiber distribution and alignment in the desired location.
Delamination can be avoided with better interlayer fusion. Finally,
the void content can be avoided that otherwise would adversely
affect the mechanical properties of fiber reinforced polymeric
composite material.
Several attempts have been made by researchers to study the
different aspects associated with the additive manufacturing pro-
cess of composite manufacturing. Biomedical applications [10], the
mechanical properties of additive manufactured composites and
their industrial applications [11], the related opportunities and
challenges with the manufacturing of multidirectional preforms
[12], 4D printing of polymeric composites [13] and the develop-
ment aspects with nanocomposites as well as composite materials
[14] are some of the prominent studies that have been carried out
by the researchers in the past. However, there still exists a lacuna
for a review that consolidates the isolated islands of knowledge into
one. With this in mind, the present work reviews the different
additive manufacturing techniques for manufacturing of fiber
reinforced polymeric composite material. Potentiality, as well as
the challenges associated with the additive manufacturing of fiber
reinforced polymeric composites, are also included within the
scope of the present work.
2. Various additive manufacturing techniques for fiber
reinforced polymeric composites
As per ASTM International Technical Committee F42 on the
additive manufacturing technologies, the different techniques of
additive manufacturing fiber reinforced polymeric composite ma-
terials can be classified into the following: powder bed fusion, sheet
lamination, photo polymerization, and material extrusion.
2.1. Powder bed fusion additive manufacturing processes
Thermal energy is the main source of energy that used to fuse
the regions of powder bed selectively. Selective laser sintering is
one of the powder bed fusion processes for polymers. Discontin-
uous fibers are the reinforcements for carrying out the selective
laser sintering process of manufacturing fiber reinforced polymeric
composite materials. Mechanical properties, as well as the physical
properties of various fibers, have been improved through the in-
clusion of nano and micro dimensioned fibers. Some of the exam-
ples in this direction include those of carbon nanofiber [15], SiC
[16], yttrium stabilized zirconia [17], carbon black [18], CNT
[19,20], glass beads [21] and nanosilica [22]. Polyamides are the
typically used thermoplastic materials as matrix [15,17]. Poly-
styrene is another matrix material that has been used with a se-
lective laser sintering process [62]. Apart form the resins, higher
deposition rates as well as better surface quality was achieved with
low power lasers for thin walled aluminium alloy parts [23].
The parts produced using the selective laser sintering process
are stronger than those produced using injection or extrusion
molding. However, the elastic modulus, as well as the strength, is
lower to the parts manufactured using conventional manufacturing
processes [18]. The major reason is higher internal porosity as well
as the poor dispersion of fibers in the powder feedstock. In-
vestigations on the effect on mechanical properties of the laser
intensity have been carried out by Arai et al. [24]. Decreased vis-
cosity can be achieved with increasing laser intensity and therefore
enhancing the overall adhesion with the glass fibers. Increasing the
laser intensity beyond a certain threshold resulted in declining
mechanical properties. The fact was attributed to the decreased
molecular weight of composite-copolymer poly powder. One of the
major restrictions in employing selective laser sintering for the
manufacturing of composites is that it can only process discontin-
uous ones [25]. Additional devices are required to explore the
possibility of manufacturing continuous fiber reinforced polymeric
composites. Effect of various parameters were studies for fabrica-
tion of 3Y-TZP dental ceramics using SLS process. The laser sintering
process was combined with the cold isotactic pressing and the
impact on mechanical properties of sintering temperature was
investigated. Better mechanical properties were revealed through
the proposed process [35].
2.2. Sheet lamination
Objects are fabricated by bonding sheets of material within this
context of the additive manufacturing process. Composite-based ad-
ditive manufacturing method and the laminated object manufacturing
falls under this category of the additive manufacturing process.
Inkjet technique is employed in case of a composite-based ad-
ditive manufacturing technique that deposits aqueous-based solu-
tion on each fiber sheet. After the deposition is completed, the
thermoplastic powder is deposited onto the fiber sheet that adheres
to the aqueous solution. Excess thermoplastic powder is removed
and the fiber sheets are stacked together, compressed and heated in
the oven so that the powdered matrix gets fused. Excess fibers are
removed using sandblasting and therefore the final product is ob-
tained. As the fibers are oriented randomly, composite-based addi-
tive manufactured parts have lower strength in comparison to that
manufactured using laminated object manufacturing [25].
In the case of the laminated object manufacturing process, parts
are built through a combination of additive as well as subtractive
techniques. In this case of sheet lamination technique, stacks of
fiber sheets are used [26]. Fiber sheets are cut using laser and the
different sheets are stacked together and bonded by pressure, heat
and adhesive. The sheet material can be any form of fiber preform.
A good fiber and interlayer adhesion were revealed with the usage
of prepreg sheets consisting of E-glass fibers and epoxy matrix. As a
result tensile as well as flexural strength were reported to be
716 MPa and 1.19 GPa respectively [26] The process of laminated
object manufacturing can be enhanced further if integrated with
the mechanism of curved layer building. The mechanism aids in the
eradication of stair case effect minimized wastage of material and
has the potential capability to align fibers continuously on the
directed curvature [27].
One of the key advantages of laminated object manufacturing is
the capability to produce high strength parts in comparison to
conventional methods. Furthermore, the need for support structure
is eliminated cent percent. However, extra sheets are required to
take care of overhanging features which could ultimately result in
wastage of material. Also, the fabrication of intricate internal fea-
tures is not possible with the laminated object manufacturing
technique owing to the restriction in the removal of unwanted
material [26].
 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278
2.3. Vat photopolymerization
Ultraviolet light is used to selectively cure photopolymer in a
vat. The commonly used technique of vat photopolymerization is
that of stereolithography for the printing of fiber reinforced poly-
meric composites. The layering effect is not obvious in this process
of additive manufacturing owing to the potential ability to print at a
higher resolution. However, one of the major restrictions associated
with this technique is that of limited materials that can be
processed.
Fiber reinforced polymeric composites have been prepared us-
ing both the continuous and discontinuous fibers through the
stereolithography process. Production of parts with low porosity
has been obtained using the stereolithography process [28,29].
Fiber reinforced polymeric composites have been developed
using stereolithography techniques with different types of discon-
tinuous nano-scale as well as micrometer-scale fibers. Some of the
examples in this category includes: glass fiber [29,56], SiC [31], bio-
glass [32], titanium carbide [33], ferromagnetic fibers [28], alpha-
alumina powder [34], graphene oxide [34] and silicate dioxide
[29]. The commonly used matrix materials for such fabrication
include: epoxy resin [36], polyester resin [37] and photosensitive
polyacrylate resin [29,39,40].
Generally, two methods are involved in the preparation of
composite materials: dispersing the fiber on the surface of the resin
[41] and secondly by premixing the matrix and the fiber rein-
forcement [28,29,31,33,36,39,42]. Polymerization can be facilitated
with the incorporation of additives into the composite. Further-
more, the additives also aid in reduced viscosity of the resin, acts to
stabilize the suspension and also acts as a coupling agent between
the matrix and the fiber. The sedimentation of fibers in the matrix
can be avoided with the addition of resin material before the
inception of each layer [43]. The viscosity of the resin can be
decreased as well as a higher concentration of fiber can be achieved
with suitable fiber surface treatment technique.
There is a need for some extra mechanism to align the fibers
owing to the reason that fibers are randomly oriented in the
composite resin [32 43]. Fiber loading as high as 60 vol% has been
achieved, a further increase in the fiber loading resulted in poor
dispersion of fibers in the resin material [31]. Also, at higher loading
of fiber, entangling of the fiber takes place that further results in
weakening of bonding between fiber and the matrix.
Generally addition of fiber reinforcement results in enhanced
mechanical properties such as tensile strength [29], hardness [36],
fracture toughness [29,31], flexural strength [31] and young's
modulus [29]. However, the achievable mechanical properties
depend to a great extent on the density, size, and shape of the fiber
reinforcement used. As for instance, negative results for tensile
strength have been reported with the addition of microsphere
[30,39]. The low density of hollow microsphere is the major reason
behind the decreased tensile strength. Variation in length of carbon
fibers and its impact on fracture toughness as well as flexural
strength was investigated by Lu et al. [31]. The fracture toughness
was revealed to be higher for 2 mm fibers while the flexural
strength was highest for 1 mm fibers. The print quality was re-
ported to be enhanced with the addition of reinforcements [29].
However, the addition of reinforcements to photocurable resin
results in a number of issues. Firstly, the addition of reinforcements
leads to increasing viscosity. The increased viscosity adversely ef-
fects the processability [29]. Reduction in depth of UV penetration
and lateral resolution has been revealed owing to the scattering of
light because of the presence of reinforcing particles in the matrix.
Therefore, a high density laser is required to process the composite
specimen. Addition of reinforcements that are transparent to the
UV radiation can aid in circumventing the aforementioned issue
269
[36]. The curing process can be completed only with the post curing
process. Stiffness of graphene based composite was enhanced
significantly with the post-thermal and UV treatments [34].
Reduction of graphene oxide was aided with such post-treatments
and was, therefore, the reason behind enhanced stiffness.
Stereolithography process has been carried out for fabrication
of continuous fiber reinforced composite materials. Carbon fiber
mats [44], carbon fiber bundles [33,45], glass [39]and e-glass fi-
bers. Manual laying process has been adopted for carrying out
fabrication of fiber reinforced polymeric composite through
stereolithography process [33,45]. Improvement in mechanical
properties such as tensile strength has been reported with the
incorporation of continuous fiber reinforcement in the resin ma-
terial [33]. E-glass, aramid nonwoven mats and carbon mats have
been incorporated in epoxy-based resins [46]. Around 50%
improvement in mechanical properties such as tensile strength as
well as elastic modulus was reported. However, due to the re-
striction associated with the consolidation process, the rein-
forcement loading couldn't be achieved beyond 20% [39].
Although, enhanced mechanical properties have been reported
they don't meet the targeted requirements due to the boor
bonding between the fiber and the matrix [33]. The poor bonding
may be attributed to the incomplete curing because of the scat-
tered UV radiation. However, the employment of post-processing
thermal treatments resulted in improvement over the mechanical
properties. Placement of fibers also plays a crucial role in
achievable mechanical properties [44] since poor placement can
result in air entrapment. Entrapped air may result in uneven
surface [33]and thereby weakening the interlayer bonding.
2.4. Material extrusion
The composite material is deposited in either filament or in
paste form in the material extrusion process. The selective depo-
sition takes place through the aid of a nozzle. The technique
through which the filament is melted and extruded is known as
fused filament fabrication [47] while it is known as liquid deposi-
tion modeling if one utilizes paste. Cost effectiveness is one of the
major advantages associated with material extrusion techniques.
Furthermore, material extrusion techniques are relatively simpler.
In order to extrude short fibers, almost no modifications are
required whereas only a few modifications are required related to
the printing head in case of extrusion of long fibers. Employability
of multiple nozzles can result in expanding the potential applica-
tion to print multi-material. However, the layering effect is one of
the major drawbacks associated with this technique of additive
manufacturing.
2.4.1. Liquid deposition modeling
In this technique of material extrusion, the liquid or material in
paste form is deposited selectively using a syringe. The syringe is
attached to a computerized numerical control machine. Till date,
reinforcements are only present in the form of discontinuous fibers.
Matrix material such as thermoplastics as well as thermosets
has been employed as matrix material in the liquid deposition
modeling technique of additive manufacturing [48,49]. Discontin-
uous reinforcements such as silicon carbide (SiC), CNT [48e51],
glass fibers [49], carbon fibers [49,50] and whiskers [50] have been
employed in this technique of material extrusion. Paste like mate-
rial is formed by mixing liquid resin with the reinforcing material.
Agglomeration is one of the major setbacks associate with some of
the reinforcements. Hence few acidic treatments are required to
ionize the reinforcing material or some suitable solvent agents can
be used as for instance polyvinylpyrrolidone [51]that aids in suit-
able dispersion mechanism.
270 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278
Thermoset resins can be processed easily in comparison to
thermoplastics while employing the liquid deposition modeling
technique. Thermosets such as epoxy resin, however, requires
specific viscoelastic as well as rheological properties to be extruded
smoothly through the nozzle. A shear-thinning behavior is the
characteristic feature of most ink dispersants. This is due to the
increasing shear rate with declining viscosity [51].
There is another variation wherein dual-cure composites are
formed through the presence of thermocurable as well as photoc-
urable components. The photocurable component aids on the one
hand in fast curing to maintain the shape, the cross-linking is
achieved by the presence of the thermocurable component. Better
mechanical properties are achieved through such variations [49].
Printing window to has been reported to be expanded to around 30
days through the inclusion of imidazole-based ionic fluids. The
processing temperatures of thermoplastics tend to decrease with
the employability of volatile solvents [50].
Work reported with epoxy resins is of significance since it de-
picts the manner of aligning fibers by controlling important pa-
rameters such as nozzle diameter and aspect ratio [50]. Although,
the printing of discontinuous fiber reinforced polymeric compos-
ites has only been accomplished.
2.4.2. Fused filament fabrication
Fused filament fabrication technique has been used to develop
fiber reinforced composite materials ranging nano-scale to
continuous fiber form. Carbon [52], glass [53], fibers of thermo-
tropic liquid crystalline polymers in long chopped for or in milli-
meter range [54], iron [55], metallic powders of copper in
micrometer range [57], graphene [58], multiwalled and single-
walled carbon nanotube [52,56] are some of the materials that have
been researched for the fabrication of composites through the
fused filament fabrication technique. Even natural fibers such as
hemp and harakeke have also been employed to fabricate poly-
meric composite using this technique [59]. The commonly used
matrix materials are thermoplastics. Few examples of thermo-
plastics requiring low processing temperatures include poly-
propylene [54], poly-lactic acid [56,60], nylon [56], acrylonitrile
butadiene styrene [52,53,57,58,61]. Polyether ether ketone and
Ultem are examples of matrix materials that require high pro-
cessing temperature.
The alignment of fibers is achieved through the shear force
between the nozzle walls and the fibers [52]. Improved mechanical
properties are normally achieved using long fibers [61] as for
instance with the incorporation of millimeter-sized carbon fiber
[52] or with the addition of singlewalled carbon nano tubes. The
larger surface area of the fiber material results in higher shear at the
interface of the fiber and matrix and is, therefore, the reason behind
enhanced mechanical properties.
Fiber loading is another relevant area of research that has been
investigated extensively and has been demonstrated to be
dependent on the reinforcement ematrix combination. Elastic
modulus increases with the fiber loading up to a certain threshold
limit [52]. Poor wettability of the fibers with the matrix materials
is the cause to be attributed towards the poor fiber-matrix inter-
face. Increase in fiber loading results in increased matrix viscosity
and lower flowability [62]. This may lead to clogging of the nozzle
[58]. Plasticizers and surfactants may be added to enhance the
fiber-matrix bonding. This will ensue in better process ability of
the material. As for instance the addition of Buna-N and linear low-
density polyethylene were added as compatibilizers and tough-
ening agents respectively with the reinforcing material in ABS [53].
The tensile strength was reported to be enhanced with the addi-
tion of 1 wt% hydrogenated Buna-N and 30 wt% of linear low-
density polyethylene.
Incorporation of fibers weakens the out-of plane tensile
strength of the composite and the strength is even lower than the
unreinforced thermoplastics [52]. The reason may be attributed to
the low conformity of the fibers to the previous layer and hence, as
a result, the contact area between the layers is reduced. Further-
more, the fibers are not aligned across and hence are not able to
reinforce the out-of-plane tensile strength.
Tensile strength of composites obtained from carbon nanotubes
reinforced in PEEK was tested and an improvement in the tensile
strength of the composite filament was revealed [62]. The tensile
strength was however decreased with the addition of higher wt% of
carbon nano tubes. The reason being the presence of more pores.
This very result explains the fact that the air gap introduces owing
to the interaction between the fiber and the reinforcing material
during the extrusion process. Therefore void formation is another
area of research which can aid in reducing the impact on me-
chanical properties.
Fused filament fabrication is convenient for short fiber reinforced
polymeric composites. This is because they are extruded in a normal
filament without the need for an extra layer. However, the fused
filament fabrication suffers from voids and porosity. Reduced tensile
strength and delamination results owing to the formation of voids in
between the extruded filaments [52]. It is more effective to incor-
porate reinforcements along the filament direction. This is because
the fibers tend to align themselves in the direction of extrusion and
thereby resulting in better anisotropy in mechanical properties [58].
The fused filament fabrication process has been used for the
fabrication of continuous fiber reinforced polymeric composites
[63e66]. Additive manufacturing can simply be accomplished by a
simple modification of the print head. A number of different ap-
proaches have been adopted to print continuous fiber reinforced
polymeric composite such as extrusion, in situ consolidation of fi-
bers and thermoplastic at the nozzle [28,30,31,33,39e65,69] and in
situ fusion of fibers and thermoplastics before extrusion [67]. In
case of in situ consolidation, viscosity effects both the traction force
as well as the viscosity of the resin. Fibers in case of in situ fusion of
fibers at the nozzle are fused with the resin at the nozzle and the
fibers are extruded automatically without the employment of any
feeding device. Certain mechanisms such as resistive heating [70],
laser cutting [70] and mechanical cutting [68] are required to cut
the fibers at the end of each composite layer. Reinforcements using
continuous fibers produces significant improvement in tensile
properties [68,71] Table 1 depicts the advantages and disadvan-
tages of various AM techniques.
3. Scope of future work
3.1. Material usability in different AM techniques
Most of the research work carried out in the domain of additive
manufactured composite materials are on the short fiber re-
inforcements. There are umpteen challenges associated with the
employability of other forms of fibers. However, challenges asso-
ciated needs to be overcome in order to have stronger materials.
Some of the research has been taken in this direction as obvious
from Table 2.
The physical, as well as the chemical properties, are inhibited by
the availability of a narrow range of commercial resins [14].
Research in this direction has led to the development of function-
alized materials with a broader range of properties such as
dielectric [88,89], electrical conductivity [19,85], thermal [86] and
piezoelectric [87]. Functionally graded materials are now being
fabricated using the AM techniques by controlling the distribution
of reinforcement spatially. Different arrangements of materials
with diverse properties can aid in the development of material with
 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278 271

Table 1
Different additive manufacturing techniques for composite materials with their advantages and disadvantages.

Techniques Advantages Disadvantages Fiber alignment

Laminated object  Low cost.  Higher wastage of material  Random fiber orientation
manufacturing  Parts with high strength can be produced.  It is relatively difficult to  Uniform direction of the fiber
 No requirement for post-processing. build parts with complex cavities.
 No requirement of support structures.
Powder bed  Support structures can be removed easily.  Rough surface finish.  Random fiber orientation
fusion  Composites with higher reinforcement of  Slow printing
loading can be achieved.  Not possible to fabricate
 Fine resolution composites with long fibers.
 Powders that remains unused can be used again  Expensive
 High porosity in the final parts.
Vat photopolymerization  Fibers can be aligned randomly.  Formation of bubbles takes place.  Random fiber orientation
 Finer resolution  Limited materials can only be used.  Along the direction of electric-field.
 Sedimentation of fiber in resin  Along the direction of magnetic-field.
 Increased resin viscosity with  Along the direction of laying.
the addition of fibers.  In accordance with the fiber pattern
 The issue with the penetration of the mat.
of UV rays.
Material extrusion  Easy to fabricate.  Degradation of the nozzle.  Along the direction of printing.
 Economical  Obvious layer-by-layer effect.
 Multi-material capability.  At higher reinforcement loading,
 Print-heads can be easily modified. nozzle gets clogged.

enhanced properties. As for instance, materials with different
permittivity can result in materials with diverse refractive indices
[88]and resonant frequencies [89]. A smart material using CF/PEEK
was developed by Yang et al. [90] that can change the shape of
electrical heating. Research work has been in progress to develop
and fabricate continuous wire polymeric composite using the
extrusion process. A successful application will ensue in the
development of thermal and mechanical sensors and heating ele-
ments that can be integrated into AM structures [86].
Multimaterial capabilities of AM techniques must be explored to
fabricate composites through selective deposition of two or more
different types of materials at different locations. The research
exploration will ultimately push the boundaries and add a new
paradigm to create and develop fiber reinforced polymeric com-
posites using AM techniques. Multimaterial capabilities have been
explored and have been used for a variety of applications such as
robotics [91], 4D printing [92], medical phantom models [93] and
biologically inspired materials [94].
Sandwich composites have been developed using multimaterial
AM techniques. Fiber reinforced facesheets [32] have been manu-
factured using honeycomb structures through the aid of additive
manufacturing techniques. Honeycomb structures have been ob-
tained by adhesively assembling sandwich core such as lattices
[95], cellular structures [32,96],etc. Fabrication of functional com-
posites through the creation of hybrid one-step process will be led
to the creation of a new paradigm in the composite design industry.
3.2. Interfacial properties
Interfacial characteristics play a critical role in deciding the
overall properties of the fabricated composite material. Effective-
ness of stress transfer depends on the interfacial shear stress which
also dictates the functional performance, toughness, off-axial
strength and environmental stability of fiber reinforced polymeric
composites [97]. Changing the composition may aid in controlling
the interfacial properties of the fabricated composites.
Research associated with the interface of the composites fabri-
cated using AM techniques is scarce. Majority of research is focused
on the bulk material properties only. The interfacial properties in
most of the studies are deduced using the SEM images [15,45].
Interfacial strength of composites is required to be studied in a
detailed approach at three different levels such as macroscopic,
mesoscopic and micro-level [98]. The interfacial adhesion between
the fibers and the matrix can be assessed using macroscopic test
methods. However, only qualitative analysis can be made using
such tests and therefore interfacial strength can't be deduced such
as. To the best of the knowledge, the quantitative assessment of the
interfacial strength hasn't been carried out till date for the additive
manufactured composites. Quantification and analysis of the
associated mechanical interactions can be assessed such as thermal
residual stress, sliding friction stress, nonbinding energy and nano-
mechanical interlocking [99,100].
Analysis of interfaces can aid in understanding the wettability
between the polymeric matrix and the fibers. Although a number of
studies are available for non-additive manufactured composites,
the studies in the domain of additive manufactured composites
have been focused primarily on fused filament fabrication [32,101],
SLA [88] and selective laser sintering [77,102].
3.3. Interlayer bonding
It is very essential to determine the bonding between layers to
assess the overall strength of the 3D printed parts. Research has
been carried out to study the interlayer bonding strength of pure
thermoplastics [103] and parameters such as tensile strength in the
z-direction, inter laminar fracture toughness [104] and shear
strength [68,105] have been studied to gauge the interlayer prop-
erties of the additive manufactured composites. In the majority of
cases, the z-direction tensile strength has been revealed to be
weaker than those in in-plane [105,106]. Hence research is required
to be directed to investigate and improve the interlayer strength of
additive manufactured composite materials and such as many
studies have been carried out and many are in progress [107e111].
3.4. Printability
The rheology of the material changes with the addition of re-
inforcements giving rise to issues associated with printability.
Hence rheology control is critical when fabricating composites
using additive manufacturing techniques. Viscosity, melt flow in-
dex and is one of the properties that has been explored and
investigated [111e118]. Viscosity is controlled through the addition
of rheology modifiers and ensures the printability of composite
materials. As for instance, PVP enhances the viscosity of CNT ink
272 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278

Table 2
Mechanical properties of composites fabricated using additive manufacturing techniques.

Fabrication Techniques Reference Composite composition Mechanical Properties

Selective laser [15] 3 wt% Carbon nanofiber reinforced in PA-12 The storage modulus of 1.2 GPa at room temperature.
sintering 4 wt% Carbon black reinforced in PA-12 Impact strength of 12 Jm 2
Flexural modulus of 1.4 GPa
Young's modulus of 1 GPa
Ultimate tensile strength of 26 MPa
[19] 4 wt% carbon nanotube reinforced into PA-12 and PU Thermal conductivity of upto 16.9 Wm 1K 1
[73] Carbon fibers with dimensions ranging 100e200 mm Tensile modulus of 6.3 GPa
reinforced in PA-12
[74] 25 wt% glass fiber in PA-12 Fracture toughness of 3.9 MPa m1/2
Ultimate tensile strength of 43.7 MPa
Tensile modulus of 2.71 GPa
[22] 3 wt% nanosilica in PA-12 Impact strength of 40.2 kJ m 2
Ultimate tensile strength of 43.7 MPa
Tensile modulus of 2.71 GPa
[16] SiC with different weight fractions: 10, 25 and 50 Tensile strength ranging 34e40.5 MPa
reinforced in PA-12 Increased loading leads to reduced strength
Higher porosity
[21] 30 wt% glass beads in PA-11 Tensile modulus of 1.7 GPa
The compressive modulus of 2.6 GPa
[17] 5 wt% YSZ with PA-6 Ultimate tensile strength of 25 MPa
[75] 10, 20, 30 wt% glass fiber in poly (propylene-co-ethylene) Ultimate tensile strength 15e20 MPa
Tensile modulus 0.7e1.15 GPa
[62] Glass fiber in polystyrene Flexural strength of 16.3 MPa
[76] 25 wt% Wollastonite fibers in PA-12 Ultimate tensile strength of 40 MPa
Tensile modulus of 3.6 GPa
Flexural creep modulus of 3.6 GPa
30 wt% Glass fiber in cPBT Ultimate tensile strength of 60 MPa
Flexural strength of 90 MPa
Impact strength of 2 kJ m 2
[77] 30 wt% carbon fibers thermally as well as HNO3 Ultimate tensile strength of 80 MPa
Young's modulus of 5.8 GPa
Flexural strength of 114 MPa
Flexural Modulus of 5.9 GPa
Laminated object [78] 55 vol% e-glass fibers in aerospace grade prepreg in epoxy resin Ultimate tensile strength of 713 MPa
manufacturing Compressive strength of 896 MPa
Flexural strength of 1190 MPa
Interlaminar shear strength of 42.6 MPa
SLA [49] Irregular SiC powders in DSM Somos 19 120 resin Flexural strength of 325 MPa
Fracture toughness of 45 MPa m1/2
[32] Bioglass in the acrylate-based monomer Biaxial strength of 40 MPa
[39] Hollow microsphere in polyacrylate resin Reduced tensile stress
[34] Graphene oxide (0.5 phr) in PEO-diacrylate Compression modulus of 11.1 MPa
Young's modulus of 0.0110 GPa
Graphene oxide (0.3 phr) in PEO-diacrylate Young's modulus of 0.0116 GPa
Compression modulus of 9.6 MPa
[29] SiO2 nanoparticles in acrylated functionalized oligomers Fracture toughness of 0.38 MPa m 1/2
Young's modulus of 1.7 GPa
[35] Nanocarbon black in visible light curing polymer The hardness of 81 mm
Ultimate tensile strength of 0.24 MPa
[30] e-glass fiber in SLA 250 photopolymer Good thermal and electrical conductivities
Ultimate tensile strength of 24.13 MPa
Young's modulus of 5.8 GPa
[39] e-glass fiber in polyacrylate resin Ultimate tensile strength of 26 MPa
Fused fiber [79] Carbon fiber and Nylon Impact strength of 82.26 kJ m 2
fabrication Glass fiber/Nylon Impact strength of 280.95 kJ m 2
Kevlar fiber and Nylon Impact strength of 184.76 kJ m 2
[80] e-glass fiber in polypropylene Flexural modulus of 13.06 GPa
[81] Carbon fiber in ABS Ultimate tensile strength of 574.44 MPa
Young's modulus of 25.86 GPa
Carbon fiber in PETG Ultimate tensile strength of 69 MPa
Young's modulus of 8.5 GPa
Carbon fiber in PLA Ultimate tensile strength of 69 MPa
Young's modulus of 9 GPa
[71] Glass fiber and Nylon Ultimate tensile strength of 575 MPa
Young's modulus of 25.86 GPa
Poisson's ratio of 0.37
Shear strength of 67.77 MPa
Compression strength (0 ) of 82 MPa
Compression strength (90 ) of 12.73 MPa
[71] Carbon fiber and Nylon Ultimate tensile strength of 701 MPa
Young's modulus of 68.08 GPa
Compression strength (0 ) of 223.06 MPa
Compression strength (90 ) of 41.83 MPa
Poisson's ratio of 0.35
 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278 273

Table 2 (continued )

Fabrication Techniques Reference Composite composition Mechanical Properties

[72] 35 vol% Kevlar fiber and nylon Ultimate tensile strength of 450 MPa
Young's modulus of 7.2 GPa
Flexural strength of 149 MPa
Indentation energy of 7.05 kJ
Flexural modulus of 14.7 MPa
[72] 41 vol% Carbon fiber and Nylon Ultimate tensile strength of 600 MPa
Young's modulus of 13 GPa
Flexural strength of 430 MPa
Flexural modulus of 38.1 MPa
Indentation energy of 6.26 kJ
[82] 8.9 vol% Recycled carbon fiber in Poly Lactic Acid Ultimate tensile strength of 260 MPa
Young's modulus of 20 GPa
Impact strength of 40 kJm 2
Flexural strength of 263 MPa
Flexural modulus of 13.3 GPa
[65] 48.3 vol% Carbon fiber and Nylon Flexural strength of 231.1 MPa
Flexural modulus of 14.17 MPa
Compressive strength of 53.3 MPa
[83] Bundles carbon fibers with epoxy resin Ultimate tensile strength of 792 MPa
Young's modulus of 161 GPa
[63] Carbon Fiber in poly lactic acid Ultimate tensile strength of 91 MPa
Flexural strength of 156 MPa
[40] 10% Kevlar and Nylon Ultimate tensile strength of 91 MPa
Young's modulus of 9 GPa
Elastic modulus of 1767 MPa
[63] Bundled carbon fiber in ABS Enhanced strength
[63] Bundled carbon fiber in PLA Ultimate tensile strength of 90 MPa
Young's modulus of 5.8 GPa
Tensile modulus of 294 MPa
[68] 34.5% Carbon fiber and Nylon Ultimate tensile strength of 475 MPa
Young's modulus of 35.7 GPa
Enhance tensile modulus
[70] CNT yarn in Ultem 1010 Ultimate tensile strength of 117 MPa
Young's modulus of 2.4 GPa
Tensile strength of 317 MPa
[38] 1 wt% CNT in PEEK Shear strength of 27 MPa
Ultimate tensile strength of 70 MPa
[66] 0.5 wt5 CNT in PLA Ultimate tensile strength of 80 MPa
Young's modulus of 1.99 GPa
[62] 6 wt% CNT in ABS Ultimate tensile strength of 47.1 MPa
Young's modulus of 2.625 MPa
[58] 4 wt% Graphene nanoplatelets Ultimate tensile strength of 35.5 MPa
Young's modulus of 2.8 GPa
Higher tensile modulus
[56] 0.2% MWCNTs in PLA Ultimate tensile strength of 55 MPa
Young's modulus of 3 GPa
47% increased tensile strength
[60] 5.6 wt% Graphene in ABS and PLA Higher mechanical strength was achieved
[52] 5 wt% SWCNTs, 5 wt% Carbon fiber and MAGNUM 231 in ABS Ultimate tensile strength of 30 MPa
Young's modulus of 1.75 GPa
[67] 4 wt% Glass fiber in PLA Ultimate tensile strength of 30 MPa
Young's modulus of 4 GPa
Impact strength of 60 Jm-1
[59] 10-30 wt% Harakeke in PP Ultimate tensile strength of 25 MPa
Young's modulus of 0.32 GPa
10-30 wt% PP Ultimate tensile strength of 15 MPa
Young's modulus of 0.3 GPa
[61] 15 wt% short fiber in ABS Ultimate tensile strength of 42 MPa
Young's modulus of 2.5 GPa
The toughness of 6.3 J m-3
[57] Copper and Iron micro-scale in ABS Ultimate tensile strength of 15 MPa
Young's modulus of 0.23 GPa
Tensile modulus of 5.4 MPa
[55] Fe3O4 in P301 Nylon Ultimate tensile strength of 4 MPa
Young's modulus of 0.054 GPa
Enhanced stiffness and thermal properties
[84] Carbon fiber in ABS Ultimate tensile strength of 38 MPa
Young's modulus of 5.9 GPa
Shear strength of 13 MPa
[62] 10 wt% Carbon fiber in the millimeter scale in PA 12 Ultimate tensile strength of 90 MPa
Young's modulus of 3.5 GPa
[52] Carbon fiber in the millimeter scale in ABS Ultimate tensile strength of 70 MPa
Young's modulus of 8.91 GPa
[53] 18 wt% glass fiber in ABS Enhanced ductility
Improved flexibility
Ultimate tensile strength of 44.6 MPa
(continued on next page)
274 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278

Table 2 (continued )

Fabrication Techniques Reference Composite composition Mechanical Properties

[54] 28 wt% Vectra A950 TLCP in Amoco PP Higher tensile modulus

Ultimate tensile strength of 45 MPa
Young's modulus of 4 GPa
Liquid deposition [48] 1 wt% MWCNTs in 30 wt% PLA Improved electrical conductivity
modeling [51] 7 wt% MWCNTs in PVP Improved electrical conductivity
[49] Carbon fibers (millimeter dimensions) in Ultimate tensile strength of 40 MPa
Bisphenol A ethoxylatediacrylate Young's modulus of 3.6 GPa
[50] SiC whiskers and carbon fibers in epoxy Longitudinal ultimate tensile strength of 66.2 MPa
Transverse ultimate tensile strength of 43.9 MPa
Longitudinal young's modulus of 24.5 GPa
Transverse young's modulus of 8.06 MPa
SiC whiskers in epoxy Longitudinal ultimate tensile strength of 96.6 MPa
Transverse ultimate tensile strength of 69.8 MPa
Longitudinal young's modulus of 16.10 GPa
Transverse young's modulus of 10.61 MPa

A comparative analysis of the different AM techniques has been depicted in Table 3.

Table 3
A comparative analysis for different AM techniques.

S.No. Technology Advantages Disadvantages

1 Stereolithography
2 Selective laser
sintering
3 Laminated object
manufacturing
4 Powder-based
fusion process
Concept prototypes can be
manufactured conveniently.
Processing time is faster.
Good surface finish and accuracy in geometry.
No need for support structures.
Parts can be produced from materials such
as plastics, metals, and ceramics.
No requirement of the support structure.
Good geometrical accuracy.
Parts are produced with less porosity.
Variety of powders can be used and processed.
Manufacturing of large components is possible.
Higher rates of deposition are possible.
Can only process materials such as resins or plastics.
Cannot process functional materials such as metals.
The enclosed chamber is required.
Porosity results in mechanically weaker composites.
Size of the parts produced is limited by the size of the enclosing chamber.
Slow build-up rate.
Post processing may be required for accurate dimensioning of the final product.
Accuracy of geometry is lower.
Stair stepping effect.
Post-processing operations are required.

used during the LDM process. However, there is a downside to this
introduction i.e., it limits the amount of surfactant that can be
added as well as results in degradation of CNTs [118].
Another important property that needs to be considered is that
of powder flow ability during the processing of composite mate-
rials. Feeding quality is affected by the powder particle size. Higher
friction between the particles occurs if extremely fine powders are
used and hence leads to printability issues [118]. Larger powder size
would result in coarser layer surface. Therefore an optimal particle
size should be adopted to minimize the printability issue.
3.5. Porosity
Material integrity is reduced with the presence of pores. Me-
chanical properties too are affected with porosity. Therefore to
maintain the material integrity it is necessary to know the cause of
porosity formation. Some voids are present due to the presence of
voids in the polymeric matrix and may even induce during the
manufacturing of the composite specimen. There are technical is-
sues that also results in the pore formation [111]such as thermal
conductivity of the material, the energy received by the material,
the thickness of the material layer etc.
4. The sustainability aspect of AM
AM is one of the emerging manufacturing processes and it directly
impacts the product life cycle which represents an important
dimension of sustainability. AM process also delivers its advantages to
other stages of the product life cycle. Although AM can be considered
as a direct substitute to the traditional manufacturing technologies, its
economic benefits can only be realized when the customized products
are produced in small batches. The number of industries adopting AM
technique is growing because of the obvious advantages and market
demonstrations of the AM techniques. For many of the organizations,
the AM technique will directly substitute the existing techniques and
for many, it will be a market entry as AM technique will lower the cost
of production for their customized products. A study on analyzing the
sustainability of fused deposition modeling was approached by Al-
Ghamdi [119] and it was revealed that by choosing optimum param-
eters, sustainable printing can be achieved. An enhanced heating
mechanism with consideration to sustainability was proposed for the
SLS process [120]. The parts were produced with better mechanical
properties with the aid of reverse engineering concepts.
Another benefit that AM provides is the freedom allowed for
designing of the product. Sustainability benefits can be reaped from
redesigning of the components, products and even the process it-
self. However, it is not possible for the design engineers and the
personnel to take advantage of the AM techniques by learning all
the associated AM competencies overnight. Such as educational
policies are required to promote educational programs that aids in
the promotion of the skills needed in the country and investing in
AM techniques can be one such paradigm shift. As far as the or-
ganizations that have experience in the usage of rapid prototyping
can more easily avail the benefits of AM techniques from the sus-
tainability point of view.
Digital designs can be produced, once the competencies asso-
ciated with design for additive manufacturing have been devel-
oped. Production of digital design can aid in the development of
spare parts as and when needed. Product life can be enhanced
through coupled modular design, refurbishment and remanu-
facturing. Such as not only the affordability of the parts increases
but also aids in promoting sustainable business models.
 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278 275

The value created through AM techniques can be linked to the AM print farms being distributed across the globe which may even
benefits associated with the resource efficiency that has economical include consumers home. AM techniques will become simple and
as well as environmental benefits. As for instance, in the case of cost effective in the coming time that end consumer will be able to
aerospace structures, a high degree of generated wastes and usage of take the printout of their product with just the click of their wrist.
high value materials can motivate in providing a strong economic
scheme for the adoption of new technologies. For companies in this
6. Supply chain and AM
domain, economic benefits are linked directly to the environmental
benefits that can provide a positive side-effect. Creation or capture of
Satisfying customer requirements with on time delivery of goods
the economic importance at times impacts the behaviors, however,
to their doorsteps has become one of the vital parameters in today's
at times there are cases wherein the social or the environmental
competitive market. The quality as well as the profitability aspect
values effects the social behaviors. One of the well-known examples
shouldn't be compromised with while looking at the on-time delivery
of such ventures is that of Filabot that have aimed to commercialize
perspective. AM has become one of the potential and key enabling
technologies by minimizing the negative environmental impacts.
solutions in the domain of supply chain management. Reduction in
Some of the opportunities being created by AM techniques with
lead times, digital inventories, minimized wastes, enhanced product
the aim of sustainable development are being realized. Resources of
quality, ability to produce complex shapes etc. are some of the po-
the organization and their cognitive capabilities are the deter-
tential benefits of adopting AM techniques over their conventional
mining factor for companies to respond to such opportunities. The
counterparts. The number of stages in the supply chain can be rescued
aforementioned factors aids in understanding as to why companies
through the AM adoption [122]. Several studies have been conducted
respond to such opportunities and what all areas are there wherein
to investigate the potential effect of AM techniques on the supply chain
the innovations may be expected to originate.
managements. Wu et al. [123] have analysed and proposed solution
Adoption of AM techniques can aid the established businesses in
models for supply chain through the centralized as well as decen-
reconsideration of their business models from the sustainability
tralized AM techniques. An example of aircraft spare parts was
point of view. Companies are now understanding the potential
considered in their study. A lack of fully functional AM supply chain
ability of AM techniques to extend the product life cycle. The loop of
was highlighted by Hasan and Rennie [124] in being a major obstacle
repair, refurbishment and remanufacturing can ultimately help
towards the increased usage of AM technique. The potential impacts of
companies in the creation of incentives for the companies and
AM methods on the supply chain design was investigated by Holm-
therefore adopt a product-service business model.
strom et al. [125]. Some of the effects on the methodologies associated
There are some potential advantages as well as challenges of
with the supply chain with the advent of AM techniques were ana-
adopting AM techniques to ultimately reach the sustainability goal.
lysed by Tuck and Hague [126] and Tuck et al. [127]. The subsequent
Educating the engineers about the potential benefits of AM, providing
impact on the mass production of customizable product was aldo
support for skills development to designers and prosumer, providing
studied by the authors. The effect of lean and agile supply chain and
certification for new companies, improvising resource efficiency,
mass customization was anaysed by Tuck et al. [128] throught three
recycling is limited by the characteristics of material, speed limita-
examples of automotive and medical domains. The impact of AM
tions of the AM techniques, higher cost of machining, limited avail-
techniques with emphasis on distributed manufacturing strategy to
ability of digital designs etc., are some of challenges associated with
minimize the cost of inventory was studied by Liu et al. [122] SCOR
adoption of AM technique with sustainability goal occupying the
model was used for the evaluation of the performances for different
protagonist role. The challenges associated with industrial applica-
configrations. The social and technical impact of AM was reviewed by
tions have been highlighted by Stavropoulos et al. [121].
Hunag et al. [129] and a comparative analysis with the existing con-
ventional supply chain was made. The benefits of AM technologies to
5. Outlook and future trends of AM
the supply chain were investigated by Janssen et al. [130]. A case study
for design with the AM of orthopedic insoles was undertaken for
Additive manufacturing is leading the pathway for digital
carrying out the investigation.
transformation in the era of Industry 4.0. AM has been considered
Most of the studies were able to identify the potential benefits of
as one of the purest digital technologies because it eliminates the
AM adoption for the supply chains. The studies identified the
usage of tooling and fixtures, minimizing the cost and wastages and
contribution of AM technologies on different associated method-
leading to sustainable business models. AM has led to a paradigm
ologies of supply chain such as agile, legality and lean. However,
shift for the manufacturing industry from labor intensive
there still lies lacuna in understanding the effect of AM on supply
manufacturing processes. AM techniques aids in digitizing the in-
chain from operations management perspective.
ventory and hence aids in saving physical spaces of warehouses.
The piles of boxes occupying much of the physical spaces have been
replaced by digital files that can be stored in the cloud and are 7. Conclusion
easily accessible as and when required.
AM techniques have also helped in distributed manufacturing The present work has provided a brief overview of the AM pro-
which enables the companies to decentralize production so that cesses used for the fabrication of composites. The resulting properties
products could be manufactured meeting closer the customer re- of the composites resulting from different AM techniques have also
quirements. Manufacturers are now able to better connect the phys- been summarized. It has been observed through various research
ical supply chain with the digital thread and such as the products could findings that the properties of continuous FRPC fabricated using AM
be managed more efficiently. Manufacturing environment can be are superior to those obtained with another form of reinforcements.
disbursed to any location that has the facility for digital manufacturing. Each of the AM techniques has its own advantages. The major chal-
The decentralization, therefore, promotes a more collaborative, effi- lenge lies in the process ability of the materials and the properties
cient and transparent supply chain. If in case, a natural disaster hits, the associated with the interlayer. Achievement of desired mechanical
AM technology will be able to move forward and sustain in compar- properties can be ensured with the proper selection of the AM tech-
ison to the traditional manufacturing approaches. nique as well as finding a suitable binder. Future scope of AM in the
Owing to the umpteen benefits, factories of the future will hybrid fabrication of composites have been highlighted and opens up fron-
manufacturing environment incorporating a larger number of small tiers for future research.
276 D. Zindani, K. Kumar / International Journal of Lightweight Materials and Manufacture 2 (2019) 267e278
Conflict of interest
The authors affirm that they have no financial affiliation
(including research funding) or involvement with any commercial
organization that has a direct financial interest in any matter
included in this article.
Disclaimer
The view(s) expressed herein are those of the author(s) and do
not reflect the official policy or position of Birla Institute of Tech-
nology, Mesra.
Funding
The authors have not received funding from any agency,
governmental or otherwise, for the work presented in this paper.
Author contributions
All authors contributed equally in the preparation of this
manuscript.
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