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Researchers at Arizona State University (ASU, Mesa, U.S.) and Colorado State University (CSU, Fort Collins, U.S.) have introduced an additive manufacturing (AM) method that enables fabrication of carbon fiber-reinforced thermoset composites without molds, ovens or support structures. By combining a thermally curable resin system with photothermal curing, the approach achieves rapid in situ rigidization of both discontinuous and continuous fiber composites, offering a scalable, energy-efficient alternative to traditional composites processing.

Published in journal, the study highlights how this technique enables fabrication of continuous fiber parts with fiber volume fractions up to 70% and void contents below 1.5%, performance metrics that are reported to rival those of autoclave-cured aerospace components. Unlike conventional methods, which require sustained oven- or autoclave curing and labor-intensive layup on custom tooling, this process cures the thermoset matrix at the point of deposition, eliminating post-curing steps and reducing overall cycle time and energy input.

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“We have integrated thermal curing directly into the print path using a compact laser source,” explains Professor Mostafa Yourdkhani, senior author of the study. “This enables us to fabricate structural composite components not just on a substrate, but in free space, without the use of molds or support materials. The result is faster, more flexible manufacturing with drastically lower energy consumption.”

The system leverages a low-power laser diode to generate localized heating via the carbon fiber reinforcement, which serves both as a load-bearing material and a photothermal conversion medium. This targeted energy input cures the thermosresponsive thermoset resin system in under one second, enabling high-speed deposition and curing of structural-grade thermoset composites. Resulting printed parts exhibited optimal mechanical performance, with tensile moduli exceeding 100 GPa and tensile strengths over 1.4 GPa in continuous fiber configurations.

Unlike UV-curable resins, which are limited by low light penetration and often require extensive postprocessing, this thermal curing approach enables complete cross-linking during printing. The thermoset polymer also offers high thermal stability, low shrinkage, strong chemical and moisture resistance, and high impact resistance, properties that are critical for demanding applications in aerospace, automotive, renewable energy and marine sectors.

The research team demonstrated both layer-by-layer and freeform printing strategies, including complex out-of-plane fiber placement and long, unsupported composite spans fabricated using a six-axis robotic arm. These capabilities showcase high geometric flexibility and performance in thermoset composite AM.

With demonstrated compatibility across various reinforcement types, including aramid, glass and carbon fibers, this method is well-positioned for applications such as structural prototyping, composite tooling, on-demand component manufacturing and field-deployable composite repairs.