Hybrid manufacturing of carbon fiber reinforced thermoplastic composites: Synergistic strategies and performance breakthroughs

Carbon fiber reinforced thermoplastic composites (CFRTP) have gained immense interest across multiple industrial sectors owing to their high specific strength, recyclability, and potential for rapid processing. However, standalone manufacturing processes are frequently hindered by intrinsic limitations. While additive manufacturing (AM) affords high geometric freedom, it is fundamentally limited by interlaminar strength and high porosity. Conversely, conventional techniques, such as compression and injection molding, offer high efficiency and superior densification, yet are constrained by prohibitive tooling costs and restricted topological flexibility. Based on recent studies, this review systematically summarizes latest advancements in hybrid manufacturing strategies, which integrate additive manufacturing with other methods, for CFRTP. According to the temporal sequence of process coupling, hybrid manufacturing is classified into three primary categories: post-consolidation of AM preforms, AM insert overmolding, and energy field assisted AM. First, the distinct characteristics and recent progress of each category are comprehensively introduced. Second, the underlying mechanisms through which hybrid strategies enhance composite performance are analyzed in depth. Furthermore, the review explores the application potential of these hybrid strategies for diverse industrial landscapes and analyzes their future perspectives. Overall, this review provides theoretical guidelines for high performance, cost-effective manufacturing of complex CFRTP components.