In recent years, the rapid development of three-dimensional (3D)-printed continuous fiber-reinforced polymer (CFRP) technology has provided novel strategies for customized manufacturing of high-performance composites. This review systematically summarizes research advancements in material systems, processing methods, mechanical performance regulation, and functional applications of this technology. Material-wise, the analysis focuses on the performance characteristics and application scenarios of carbon fibers, glass fibers, and natural fibers, alongside discussions on the processing behaviors of thermoplastic matrices such as polyetheretherketone (PEEK). At the process level, the advantages and limitations of fused deposition modeling (FDM) and photopolymerization techniques are compared, with emphasis on their impact on fiber–matrix interfaces. The review further examines the regulatory mechanisms of fiber orientation, volume fraction, and other parameters on mechanical properties, as well as implementation pathways for functional designs, such as electrical conductivity and self-sensing capabilities. Application case studies in aerospace lightweight structures and automotive energy-absorbing components are comprehensively analyzed. Current challenges are highlighted, and future directions proposed, including artificial intelligence (AI)-driven process optimization and multi-material hybrid manufacturing. This review aims to provide a comprehensive assessment of the current achievements in 3D printing CFRP technology and a forward-looking analysis of existing challenges, offering a systematic reference for accelerating the transformation of 3D printing CFRP technology from laboratory research to industrial-scale implementation.

New energy vehicles face a critical challenge in balancing the thermal safety management of high-specific-energy battery systems with the simultaneous improvement of energy density. With the large-scale application of high-energy-density systems such as silicon-based anodes and solid-state batteries, their inherent thermal runaway risks pose severe challenges to battery thermal management systems (BTMS). Currently, the thermal insulation performance, temperature resistance, and fire protection capabilities of flame-retardant materials (e.g., foam cotton, fiber felts) used in automotive batteries are inadequate to meet the demands of intense combustion and high temperatures generated during thermal failure in high-energy-density batteries. Against this backdrop, thermal insulation and fireproof aerogel materials are emerging as a revolutionary solution for the next generation of power battery thermal protection systems. Leveraging their nanoporous structure’s exceptional thermal insulation properties (thermal conductivity of 0.013–0.018 W/(m·K) at room temperature) and extreme fire resistance (temperature resistance > 1100 °C/UL94 V-0 flame retardancy), aerogels are gaining prominence. This article provides a systematic review of thermal runaway phenomena in automotive batteries and corresponding protective measures. It highlights recent breakthroughs in the selection of material systems, optimization of preparation processes, and fiber–matrix composite technologies for automotive fireproof aerogel composites. The core engineering values of these materials, such as blocking thermal runaway propagation, reducing system weight, and improving volumetric efficiency, are quantitatively validated. Furthermore, the paper explores future research directions, including the development of low-cost aerogel composites and the design of organic–inorganic hybrid composite structures, aiming to provide a foundation and industrial pathway for the research and development of next-generation high-performance battery thermal management systems.

Thermoplastic composite structures possess superior properties compared with thermosetting composites, including recyclability and high damage tolerance. However, the poor adhesion properties of thermoplastic composites make their joining process challenging. In this research, three bonding techniques, namely adhesive, mechanical joining, and hybrid bonding, are investigated using lap shear specimens to evaluate their mechanical properties and failure modes. The stress distributions at the joints of the three bonding techniques are analyzed by numerical simulation. The findings demonstrate that hybrid bonding enhances the strength of composite joints, albeit at the expense of some stiffness due to the presence of an open hole. This method is particularly suitable for applications that necessitate robust connections requiring high strength.