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We have developed a novel extrusion-based 3D printing technique that can achieve a resolution of 0.51 mm layer thickness, and catalyst loading of 44% and 90.5% before and after drying, respectively.

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The disclosure is directed to optimized fiber geometries for use in carbon fiber reinforced polymers with increased compressive strength per unit cost. The disclosed fiber geometries reduce the material processing costs as well as increase the compressive strength.

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This manufacturing method uses multifunctional materials distributed volumetrically to generate a stiffness-based architecture, where continuous surfaces can be created from flat, rapidly produced geometries.