Three-dimensional printing of continuous carbon fiber/epoxy composites (CCF/EPCs) is an emerging additive manufacturing technology for fiber-reinforced polymer composites and has wide application prospects. However, the 3D printing parameters and their relationship with the mechanical properties of the final printed samples have not been fully investigated in a computational and quantifiable way. This paper presents a sensitivity analysis (SA)-based parameter optimization framework for the 3D printing of CCF/EPCs. A surrogate model for a process parameter–mechanical property relationship was established by support vector regression (SVR) analysis of the experimental data on flexural strength and flexural modulus under different process parameters. An SA was then performed on the SVR surrogate model to calculate the importance of each individual 3D printing parameter on the mechanical properties of the printed samples. Based on the SA results, the optimal 3D printing parameters and the corresponding flexural strength and flexural modulus of the printed samples were predicted and verified by experiments. The results showed that the proposed framework can serve as a high-accuracy tool to optimize the 3D printing parameters for the additive manufacturing of CCF/EPCs.

Materials with high strength and toughness have always been pursued by academic and industrial communities. This work presented a novel hybrid brick-and-mortar-like structure by introducing the wavy structure of the woodpecker beak for enhanced mechanical performance. The effects of tablet waviness and tablet wave number on the mechanical performance of the bio-inspired composites were analyzed. Compared with nacre-like composites with a flat tablet, the strength, stiffness and toughness of the novel hybrid nacre-like composite with tablet wave surface increased by up to 191.3%, 46.6% and 811.0%, respectively. The novel failure mode combining soft phase failure and tablet fracture revealed the key to the high toughness of composites. Finite element simulations were conducted to further explore the deformation and stress distribution of the hybrid brick-and-mortar-like structure. It showed that the hybrid brick-and-mortar-like structure can achieve a much better load transfer, which leads to greater tensile deformation in tablet before fracture, thus improving strength and energy absorption. These investigations have implications in the design of composites with high mechanical performance for aerospace, automobile and other manufacturing industries.