Optimization of Hot Roller Compaction Process Parameters and Microstructure Control Mechanism for 3D-Printed Continuous Fiber-Reinforced Composites 


Vol. 27,  No. 2, pp. 913-922, Feb.  2026
10.1007/s12221-025-01249-9


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  Abstract

This study systematically investigates the effects of hot roller compaction process parameters (temperature, pressure, speed) on the mechanical properties and microstructure of 3D-printed continuous fiber-reinforced composites (continuous FRPs). Through comparative and orthogonal experiments combined with SEM characterization, two quantitative models were established to elucidate the underlying mechanisms: (1) a Weibull porosity–tensile strength probabilistic model demonstrating that reduced porosity (from 6.2 to 1.1%) contributes to a 11.5% strength enhancement, and (2) a modified Halpin–Tsai fiber orientation-equivalent modulus model showing improved fiber alignment (from 18.3° to 5.2° standard deviation) increases modulus by 23%. The synergistic optimization of these mechanisms through roller compaction (1 kg, 190 °C, 7 mm/s) achieved a 37% strength improvement (2410.2 N) beyond fiber reinforcement alone, while simultaneously reducing porosity and enhancing fiber orientation. These models provide fundamental insights into the microstructure–property relationships and establish an optimized parameter window for high-performance continuous FRP additive manufacturing. The findings offer both theoretical guidance and practical solutions for improving the mechanical performance of 3D-printed continuous fiber-reinforced composites.

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  Cite this article

[IEEE Style]

Y. Kang, J. Li, Y. Fang, J. Liu, "Optimization of Hot Roller Compaction Process Parameters and Microstructure Control Mechanism for 3D-Printed Continuous Fiber-Reinforced Composites," Fibers and Polymers, vol. 27, no. 2, pp. 913-922, 2026. DOI: 10.1007/s12221-025-01249-9.

[ACM Style]

Yuzhu Kang, Jiye Li, Yuanbo Fang, and Jiang Liu. 2026. Optimization of Hot Roller Compaction Process Parameters and Microstructure Control Mechanism for 3D-Printed Continuous Fiber-Reinforced Composites. Fibers and Polymers, 27, 2, (2026), 913-922. DOI: 10.1007/s12221-025-01249-9.

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