Materials Today: Proceedings 64 (2022) 615–619

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Materials Today: Proceedings

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3D printing of composite materials: A short review

O Sai Saran ⇑, A Prudhvidhar Reddy, L Chaturya, M Pavan Kumar
Department of Mechanical Engineering, MLR Institute of Technology, Dundigal, Hyderabad, Telangana 500043, India

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

Article history: Reduced wastage of material, design flexibility and the competence to manufacture complex structures
Available online 24 May 2022 have led to the adoption of 3D printing technology in automotive, aviation, medical and other engineer-
ing sectors. Furthermore, research in 3D printing has generated enormous opportunities for academicians
Keywords: and scientists to create complicated structures with desired properties. In this short review, recent
3D printing research works on the three-dimensional printing of composite materials is provided by highlighting
Additive manufacturing the materials utilized, technologies adopted and the challenges faced. Reinforcing particulate fillers
Composite filament
and fibres incorporated in different 3D printable thermoplastic matrix systems are discussed.
Review
Typically, the properties and performances of 3D printed composite parts for different applications are
presented.
Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advanced Materials for Innovation and Sustainability.

1. Introduction semi-liquid state material layer-by-layer onto a heated printing

bed. The detailed description of the process is as followed:
3D printing or Additive Manufacturing (AM) is an evolutionary
transformative technique for the industrial production of complex
3D shapes easier to manufacture. In additive manufacturing the
material’s successive layers are fabricated by computer software
and algorithms to fabricate an object with desired dimentions.3D
printing has the leverage of achieving any shape or geometry com-
pared to the conventional machining or fabricating process. An
additive manufacturing machine or 3D printer is a machine, which
uses inkjets (in various methods) to deposit hot extruded layers of
thermoplastic material over a powdered bed in a layer by layer
pattern to attain the desired geometry of 3D parts. These machines
are already being used in various sectors like aerospace, commer-
cial, manufacturing and medical industries.
1.1. Fused deposition modelling (FDM)
Fused Deposition Modeling (FDM) or Fused Filament Fabrica-
tion (FFF) is a 3D printing process in which the FDM printer, uses
the heated filament and deposits the material layer by layer to
accomplish the expected outcome [1]. The thermoplastic filament
is heated at a particular temperature as per the material to get into
a semi-liquid state, and a multi-axis extrusion head deposits the
⇑ Corresponding author.
E-mail address: saranogoti@gmail.com (O Sai Saran).
 The thermoplastic filament spool is loaded into the printer. The
heating procedure is then initiated and once the nozzle reaches
the required temperature, the heated filament in a semi-liquid
state is fed into the extrusion head.
 A 3-axis coordinate system (X-axis, Y-axis and Z-axis) is con-
nected to the extrusion head which helps the head move in
three-dimensional space. Thin strands of thermoplastic fibre
are extruded and are kept in foreordained area layer-by-layer,
where the filament cools down and gets hardened after some
time. Depending on the type of FDM Module, various cooling
fans are attached to the extrusion head to speed up the cooling
of the kept fibre on the hot plate.
 After depositing the skeleton of the object on the heated plate,
multiple extrusion head passes are required to fill the inner vol-
ume. When the base layer is filled, the forming stage drops
down or the expulsion head moves up (Depending on the
FDM framework) [2]. Then, at that point, the subsequent layer
is saved and this cycle is rehashed over until the part is finished
[3].
I. Advantages and disadvantages of FDM
 FDM method is a cost-effective method of fabricating proto-
types and thermoplastic parts.
 It has a relatively simpler input compared to other techniques.

https://doi.org/10.1016/j.matpr.2022.05.144
2214-7853/Copyright Ó 2022 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advanced Materials for Innovation and Sustainability.
O Sai Saran, A Prudhvidhar Reddy, L Chaturya et al.
 FDM has material flexibility with a wide range of infused ther-
moplastics and exotic filaments.
 A common limitation of using FDM is the low-resolution output
due to its layer-by-layer finish.
 Lacks long term durability.
1.2. 3D-Printing applications
I. 3D Printing in construction
3D printing is being increasingly used in the construction sector
for constructing commercial apartments, residential buildings,
bridges and viaducts. The world’s first 3D printed commercial
apartment building was printed by PERI using COBOD printer
and the project was finished in November 2020 (see Fig. 1) [4].
PERI is capable of printing multiple floors of the commercial apart-
ment building with COBOD’s (a partnered company) BOD2 printer.
This printer is a modular build, which moves over a metal frame in
3-axes. BOD2 printer is capable of attaining 1 m/s printing speed.
II. 3D printing applications in aerospace
NASA and SpaceX have been heavily investing and using 3D
printing technology to manufacture their rocket SpaceX chambers
etc. On June 2nd,2020, NASA unveiled their project named ‘‘Rapid
Analysis and Manufacturing Propulsion Technology (RAMPT)”,
which uses the direct energy deposition technique of 3D printing
[5]. RAMPT aims to cut costs and production times for manufactur-
ing rockets that will be used to put humans on Mars (see Fig. 2).
The direct energy deposition method of 3D printing has a multi-
axis mechanical arm for filament deposition onto the heated sur-
face. RAMPT uses lasers for filament melting, deposition and mate-
rial solidification. This method of 3D printing is very time efficient
in printing aerospace nozzles (RAMPT is capable of printing nozzles
in months compared to years in the case of conventional manufac-
turing). This system has the leverage of having less part count since
fewer individual parts have to be printed.
III. 3D printing applications in the medical industry
3D printing technology is a boon for the health sector, where
biomaterials can be printed in desired shape and size. For the first
time in history, it is witnessed that synthetic human body parts are
printed accurately. Lifesaving surgeries like heart transplants or
tissue transplants are being achieved without donors and in a very
short period (see Fig. 3) [6,7].
In this review article, the state-of-the-art research on the three-
dimensional printing of composite materials is provided by high-
lighting the materials utilized, technologies adopted and the chal-
Fig. 1. (a) 3D-printed layers stacked; (b) Photograph of 3D-Printed Construction floor. [4].
616
Materials Today: Proceedings 64 (2022) 615–619
lenges faced. Typically, the properties and performances of 3D
printed composite materials for various applications are presented.
A material’s mechanical strength and stiffness depend on its core
shape. Flexible core designs generated through continuous carbon
fibres can attain desired stiffness and strength. To produce com-
posite 3D printed parts, at first, hybrid filaments are to be manu-
factured and later they are melted and extruded through printer
heads.
2. Fibre reinforced composite filament fabrication
Composite filament fabrication involves creating a printable fil-
ament with reinforcement and matrix materials. Here, reinforce-
ment material could be continuous or discontinuous fibres and
the matrix material will one of 3D printable polymeric materials
which includes PLA, ABS, nylon etc. The role of reinforcement is
to provide strength and stiffness to the filament whereas matrix
protects the reinforcing material from adverse environment such
as abrasion, etc. The selection of matrix and reinforcement materi-
als should be in such a way that both are compitable in terms of
physical adhesion, chemically not reacting and with similar ther-
mal expansion coefficients [8]. Some of the matrix and reinforce-
ment materials that are used in composite filament fabrication
are given Table 1.
Polymer process parameters plays a crucial role in determining
the end filament properties. In general, FDM demands polymer fil-
aments which melts quickly and cools faster to achieve dimen-
sional accuracy to the components. In this context, crystalline
polymers are avoided as they shrink causing warping of the printed
parts [12,13]. Continuous filament of constant diameter with min-
imal strains is sought for the better printing.
The rheological behavior of polymer to be understood with
respect to the nozzle temperature and shear rate. High shear rate
can cause polymer degradation as the polymeric chain stretch
and entangle [14,15], so, in general, low shear rates are preferred
for FDM technique. Nozzle temperature and bed temperature are
to be carefully selected such that base layers of polymer can adhere
firmly to the bed. Glassy state of polymer during layer-by-layer
printing is to be ensured for better interlayer adhesion [16].
3. 3D printing of composites
3.1. Fiber reinforced composite materials
The early industry used materials such as polycarbonate (PC),
poly (acrylonitrile–butadienestyrene) for FDM components have
no solidarity to create completely utilitarian parts. The progress
O Sai Saran, A Prudhvidhar Reddy, L Chaturya et al. Materials Today: Proceedings 64 (2022) 615–619

Fig. 2. (a) 3D-printed Divergent Nozzle; (b) Photograph of 3D-Printing aerospace [5].

Fig. 3. (a) 3D-printed Prosthetic Arm [6], (b) Photo of 3D-Printed Human Organ[7].

Table 1
Some of the matrix and reinforcement materials that are used for composite filament fabrication.

Material type Material Density (g/cm3) Tensile modulus (GPa) Flexural modulus (GPa) References
Matrix PLA 1.25 2.02 2.392 [9]
ABS 1.04 0.998 1.9 [10,11]
Nylon 1.1 0.94 0.84 [10,11]
Reinforcement Carbon 1.4 54 51 [10]
Kevlar 1.2 27 26 [9,10]
Glass fibres 1.5 21 22 [9,10]

of a fibre-reinforced polymer lattice has beaten this impediment, in
turn it expanded the scope of FDM and other 3D printed parts for
variety of industrial needs [17].
 Poly Lactic Acid (PLA) based Composites
A new method of printing continuous fibre reinforced compos-
ites through nozzle impregnation was first accomplished by Mat-
suzaki [18]. This empowered development of 3D printable fiber
enabled thermoplastics for FDM. The control of fibre feed rate
and polymer lattice at each area has been carefully designed to
obtain advanced material for underlying uprightness. Carbon fibre
tows or yarns of jute fibres and PLA matrix were independenly pro-
vided to the 3D printer.
Both the fiber and filaments get impregnated in the warmed
spout. The examples get imprinted in the longitudinal heading,
corresponding to the course of fiber arrangement. Author Nayna
discussed about an optimized rapid prototyping of 3D printed
carbon-based PLA composites [19]. In the article, a nozzle which
uniformly mixes the PLA resin and carbon fiber was utilized.
Improved interface bonding between carbon fiber and PLA resin
was observed where their experimental test results on tensile
strength and flexural strength shown improvements upto 13.4%
and 164%, respectively. The SEM images of fractured surfaces
depicted good fiber and matrix interface between them through
pre-processed carbon fiber printing technology. Song and his group
have developed a new degradable eco-friendly plastic through
eucalyptus wood powder reinforced PLA, which demonstrated
improved tensile strength by 10 MPa over pure PLA [20].
 Polyether-ether-ketone (PEEK) based composites
Polyether-ether-ketone (PEEK) is a bio-compatible polymer,
which has tremendous applications in dental implants and ortho-
paedics. Xinting Han and co-workers have studied the bio-
compatibility and cell adhesions of of FDM printed pure and carbon
fibre reinforced PEEK composites [17]. Their studies revealed no
toxic materials present in the samples. Surface treatments con-
ducted on the samples have shown no significant increment of
cytotoxicity. In addition, their mechanical properties includes ten-
sile strength, modulus, bending and compression strengths were
considerably improved, which highlighted the potential applica-
tons of carbon fibre reinforced PEEK composites for the human
bones, skull implants, osteosynthesis plates, etc.
 Epoxy resin based composites

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O Sai Saran, A Prudhvidhar Reddy, L Chaturya et al.
Lewicki and his team demonstrated the first carbon fibre rein-
forced aromatic resin composite system printed through controlled
micro extrusion of direct ink writing (DIW) 3D printing technique
[21]. It is realised through a new homopolymerized epoxide based
resin. It allowed them to order the fibre arrangement in the resin
system which has outperformed the mechanical performances
over randomly aligned fibre reinforced composites. They demon-
strated the highest possible volume fraction and aspect ration of
carbon fibres in the matrix to the date. They adjusted the fiber part
of the gum and carbon fiber liquid in 3 aspects through a miniature
expulsion and restored it into muddled calculations. As a result, the
materials mechanical properties were significantly improved. With
the help of CAD software, they have optimized the degree of fiber
alignment inside and extruded filament.
3.2. Particle reinforced composites
Reinforced composites support high tensile, compressive and
shear strengths. Materials in powder form or in particulate form
are quite easier to mix with the polymers. Filaments produced with
modified polymer system are being employed for producing their
composite 3D parts. In general, powders or particulates of size less
than 2.5l, materials in sheet form i.e. platelets (eg. Graphene), hol-
low spheres, short fibres (eg. Fiberglass) or special materials such
as fullerene, carbon nanotubes are commonly used materials for
printable particulate composites [22]. Here, particulate material
serves as reinforcing material and polymer as binding matrix.
 Polycarbonate
Corey M. Sheela and co-workers have focussed on the develop-
ment of 3D printable Tungsten-Polycarbonate Polymer Matrix
Composite for space applications [22]. The portrayal of tungsten-
doped polycarbonate polymer grid composites was chosen for
planning space x-beam safeguard applications. The selection of
tungsten is based on its high hardness and  beam protecting
capacity, and in addition, non-reactivity during substance func-
tionalization at an expulsion temperature. It has been found out
that polycarbonate–tungsten polymer matrix was printable and
demonstrated an improvement of about 10% in shielding capabili-
ties at 0.3% loadings of tungsten. No significant change in permit-
tivity was observed within GHz range. Hence, no electro-
magnetic characteristic degradation was observed. To determine
mechanical properties several tests and studies such as dynamic
motion analysis (DMA), tensile testing and impact testing were
done. DMA analysis has shown a proportional relation between
tungsten loading and storage modulus. This study has concluded
that tungsten micro particles within the 3D printable polymer
matrix composite were able to demonstrate X-ray shielding
capabilities.
 ABS Composites
The tribological performances of Nylon6-Al-Al2O3 and ABS parts
were evaluated by Singh et al. [23]. They examined the sliding
wear behaviour of FDM-built parts at 3 different concentrations
of Al and Al2O3 (5, 10, 15 and 20 wt%) at a sliding velocity of
1.36 m/s for durations of 5 and 10 min. They identified that the
presence of Al and Al2O3 in the Nylon 6 matrix, the composite
materials have shown higher wear resistance values than pure
ABS material.
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Materials Today: Proceedings 64 (2022) 615–619
4. Properties of 3D-Printed composite parts
4.1. Mechanical properties
3D printing materials often limited in mechanical strength val-
ues have been reinforced with fillers to accomplish their compos-
ites with improved performances. In 2015, Ning et al. reportedly
prepared carbon fibres incorporated thermoplastic composite parts
and observed with enhanced flexural properties i.e. strength, mod-
ulus and toughness improving by 12%, 17% and 22%, respectively at
relatively lower as low as 5 wt% carbon fibres [24]. As the carbon
fibres content was increased in the system, porosity raised in com-
posites leading to the deteriorated properties. El-Shekeil and
coworkers added kenaf fibres and cocoa pod husk fibres into the
polyurethane matrix, where their composites were observed with
improved tensile and flexural properties [25,26]. In another work,
SiC whiskers and carbon fibres are included in the epoxy resin,
where alignment of fibres were carefully controlle to resemble
the whole structure as a natural balsa wood [27]. On the other
hand, natural fibres were printed for hygromorphic biocomposites
and demonstrated its bending response agaist moisture gradient
[28,29].
4.2. Thermal properties
3D printed can be achieved with highly thermal insulating
properties when insulating fillers are added to the matrix, simi-
larly, they can be made to achieve superior conductivity properties
with high thermal conductivity fillers [29]. For example, recently a
commercially available polymer matrix was introduced with gra-
phene flakes. Graphene was oxidized into graphene oxide (GO),
which was mixed in N-methyl pyrrolidone (NMP). ABS was mixed
with NMP suspension to produce GO-ABS dispersion. Finally,
chemical reduction of graphene oxide was conducted to encourage
G-ABS. This G-ABS composite was melted at 210 degrees Celsius in
3D printer FDM nozzle to fabricate highly thermal conducting
composites. The saturation limit for adding graphene concentra-
tion was observed at 7.4 wt%, beyond which the filler material
noticibly chocking FDM printer nozzle [30].
4.3. Optical properties
Ink-jet 3D printing has attracted many researchers because of
its ability to produced electrochromic devices. It enabld the cre-
ation of high resolution patterns with very less amount of material
[31,32]. Quantum dots filled polyisobutylene has been studied to
create light converting thin films for AC electroluminescent dis-
plays [33]. The composites demonstrated displays with full bright-
ness and high power consumption. Similarly, conducting polymers
with silica particles were studied for developing devices which can
change its color against applied voltages [34]. Other quantum dots,
such as CdSe/ZnS polymer composites were also studied for
coloured thin films [35].
5. Conclusions
3D printing technology is gaining an inordinate amount of
recognition and development in the manufacturing industry, due
to its more reliable and automated approach of producing high
performance composite parts which were handmade till now.
The rise of 3D printing technology has redefined the materials cho-
sen for certain application due to their cost effectiveness and reli-
able output. Studies were conducted on different matrix materials
such as PLA, ABS, PC etc. along with reinforcing filler materials and
reinforced fibres. Processing difficulties were being understood
O Sai Saran, A Prudhvidhar Reddy, L Chaturya et al.
and solutions were drawn to produce components with superior
properties. 3D printed hybrid composite parts has a huge scope
of renovating manufacturing abilities for demanding applications.
Future research works on 3D Printing of composites can be rely
on improving the methods for fusing continuous fibres with
matrix.
CRediT authorship contribution statement
O Sai Saran: Conceptualization, Validation, Writing – review &
editing. A Prudhvidhar Reddy: Conceptualization, Writing – orig-
inal draft. L Chaturya: Writing – original draft. M Pavan Kumar:
Conceptualization, Writing – original draft.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
Acknowledgments
Authors are thankful to Dr. Lokasani Bhanuprakash for the help
in documenting the manuscript.
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