ADVANCEMENTS IN 3D PRINTING TECHNIQUES FOR POLYMER FIBER-REINFORCED TEXTILE COMPOSITES: A SYSTEMATIC LITERATURE REVIEW

Abstract

The advancement of 3D printing techniques for polymer fiber-reinforced textile composites has opened new frontiers in lightweight, high-performance material fabrication, significantly impacting industries such as aerospace, automotive, biomedical engineering, and smart textiles. By integrating textile-based reinforcements—such as woven, knitted, or nonwoven fibers—into polymer matrices, additive manufacturing enables the creation of geometrically complex, customizable, and multifunctional structures with enhanced mechanical properties and design flexibility. These composites benefit from the inherent advantages of textile architectures, including superior fiber alignment, multi-directional load distribution, and high surface area for bonding, which collectively contribute to improved tensile strength, impact resistance, and durability. However, challenges persist in optimizing interfacial adhesion between textile fibers and polymer matrices, achieving precise fiber orientation, minimizing voids and porosity, and addressing anisotropic behavior in the printed components. This systematic literature review examines the interplay between material selection, fiber configuration, printing processes, and structural performance in the development of 3D-printed textile composites. It critically evaluates various additive manufacturing methods—such as fused deposition modeling (FDM), powder-bed fusion, and vat photopolymerization—and explores how they interact with different textile fiber forms and polymer systems to influence mechanical behavior and functional outcomes. The review also identifies persistent research gaps, including limited understanding of fiber–matrix interlocking mechanisms, inconsistent quality control during printing, and underexplored use of bio-based or recyclable textile composites. Real-world applications in sectors requiring lightweight and load-bearing components—such as aerospace panels, automotive interiors, orthopedic devices, and wearable electronics—demonstrate the growing importance of these composites in delivering sustainable and innovative engineering solutions. Looking ahead, the integration of artificial intelligence for real-time process optimization, multi-scale modeling for performance prediction, and in-situ monitoring for quality assurance is anticipated to further enhance the reliability, performance, and eco-efficiency of 3D-printed fiber-reinforced textile composites, positioning them as a critical area of interdisciplinary innovation bridging textile engineering, polymer science, and advanced manufacturing.