Composite 3D Printing and Its Applications

Composite 3D printing represents a transformative advancement in additive manufacturing, enabling the production of high-performance components by combining the design flexibility of 3D printing with the enhanced material properties of composites. This technology allows for the integration of reinforcement materials such as carbon fibers, glass fibers, or nanoparticles into polymer, metal, or ceramic matrices, resulting in structures with superior strength, durability, and functionality. The evolution of hardware, software, and feedstock materials has significantly broadened the scope of applications, from aerospace and automotive engineering to biomedical devices and consumer products. As industries strive for lightweight, custom, and sustainable solutions, composite 3D printing offers a promising pathway to meet these demands through optimized material utilization and design-driven innovation.

The aim of this Research Topic is to address the critical challenges and unlock the full potential of composite 3D printing in real-world applications. Despite its promising advantages—such as improved strength-to-weight ratios, customizability, and reduced material waste—the technology still faces significant hurdles. These include limited understanding of process-material-property relationships, anisotropic behavior of printed parts, interfacial bonding issues between matrix and reinforcement, and the need for multi-material integration. Furthermore, the lack of standardized testing and design methodologies hampers broader industrial adoption. To overcome these challenges, recent advances have focused on process optimization, hybrid manufacturing approaches, in-situ monitoring, and machine learning-assisted design. Innovations in material development, such as continuous fiber-reinforced filaments and self-healing composites, are also expanding the capabilities of additive manufacturing. This Research Topic invites contributions that explore theoretical modeling, experimental techniques, application-specific case studies, and novel material systems. The goal is to consolidate current knowledge, stimulate interdisciplinary collaboration, and accelerate the deployment of composite 3D printing technologies in sectors like aerospace, healthcare, construction, and electronics.

This Research Topic aims to encompass the latest developments, challenges, and applications of composite 3D printing technologies. We invite original research, reviews, and case studies that focus on a broad range of themes, including but not limited to:

• Design, modeling, and simulation of composite 3D printed structures

• Development of novel composite materials, including fiber-reinforced polymers and nanocomposites

• Process optimization and hybrid manufacturing techniques

• Mechanical, thermal, and functional characterization of printed composites

• Applications in aerospace, biomedical engineering, automotive, and consumer products

• Environmental and sustainability aspects of composite 3D printing

• AI and data-driven approaches in design and quality control

We encourage submissions that highlight interdisciplinary innovation, propose new methodologies, or provide critical insights into practical implementation and scalability. Both fundamental studies and industry-relevant developments are welcome.

Article types and fees

This Research Topic accepts the following article types, unless otherwise specified in the Research Topic description:

• Brief Research Report
• Editorial
• FAIR² Data
• FAIR² DATA Direct Submission
• Hypothesis and Theory
• Methods
• Mini Review
• Opinion
• Original Research
• ... View all formats

Articles that are accepted for publication by our external editors following rigorous peer review incur a publishing fee charged to Authors, institutions, or funders.

Article types

This Research Topic accepts the following article types, unless otherwise specified in the Research Topic description:

• Brief Research Report
• Editorial
• FAIR² Data
• FAIR² DATA Direct Submission
• Hypothesis and Theory
• Methods
• Mini Review
• Opinion
• Original Research
• Perspective
• Review

Keywords: Additive Manufacturing, 3D Printing Technologies, Composite Materials, Fiber-Reinforced Polymers, Smart Materials, Mechanical Properties, Advanced Manufacturing Applications, Sustainable Manufacturing

Important note: All contributions to this Research Topic must be within the scope of the section and journal to which they are submitted, as defined in their mission statements. Frontiers reserves the right to guide an out-of-scope manuscript to a more suitable section or journal at any stage of peer review.