Mechanical behavior, process innovations, and future directions of 3d-printed continuous fiber-reinforced polymeric lattice structures: A comprehensive review

Continuous fiber-reinforced polymeric lattice structures (CFRPLSs) represent a significant advancement in materials science and lightweight structural engineering, owing to their superior strength-to-weight ratios and enhanced mechanical performance. This comprehensive review covers developments in the additive manufacturing of CFRPLSs from 2014 to 2025, offering a detailed classification based on reinforcement types, matrix materials, printing techniques, and geometric configurations. The study meticulously examines how lattice architecture, fiber type, matrix composition, and processing parameters affect key mechanical properties, including elastic modulus, tensile strength, and impact resistance. The integration of continuous fibers within polymeric lattices significantly enhances structural behavior, enabling the fabrication of multifunctional components with tailored properties. Through comparative analyses using tables and graphical representations, the review highlights the critical roles of geometry, manufacturing processes, and fiber reinforcement strategies. Additionally, it addresses prevailing technical challenges, including optimizing fiber–matrix interfacial bonding, achieving precise lattice control, and predicting mechanical responses under complex loading scenarios. By identifying research gaps and proposing future directions, this work serves as a valuable roadmap for researchers and engineers focused on designing and manufacturing next-generation lightweight, high-performance lattice structures. Ultimately, the findings contribute to the advancement of innovative material solutions and the expansion of the practical applications of CFRPLSs across diverse engineering fields.