Strategies for overcoming the technological impasse in the planning of extrusion for continuous fiber reinforced polymer matrix composites in FFF software

Polymer matrix composites reinforced with continuous fibers (CFRP), particularly when used in additive manufacturing (AM), are materials of significant interest in the engineering field. The fibers enhance mechanical properties due to selective reinforcement orientation in the matrix and reduce the relative density of the printed object. Generally, composites excel in aerospace, automotive, sports, and medical applications. However, several challenges remain in three-dimensional printing of objects with complex geometries and three-dimensional control of mechanical properties, as CFRP AM requires specific CAD-CAE-CAM software and 3D printers. This article discusses CFRP, emphasizing data analysis and comparison between Aura® and Cura® software, as well as technological impasses and potential resolutions for CFRP AM development. Furthermore, research investigation involves detecting design actions through parameter changes and code adaptation to achieve similar results from private software in FFF software. Conclusions highlight the need for further research development related to the topic, software availability for study and application in CFRP 3D printing, and the necessity of developing national technologies such as software (CAD-CAE-CAM), new materials, processes, printers, and AM services in this segment. Additionally, the research presents potential solutions to achieve results similar to private software using FFF-directed software, such as making changes in G code, defining new commands, and applying strategies based on printing parameters.