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Engineering Science in
Additive Manufacturing AM-CFRP structures for EMWA properties

terahertz bands). Most polymer-based 3D printing Electrical traces, magnetic nanoparticles, and dielectric
filaments do not have magnetic loss mechanisms, limiting layers might be accurately deposited in a single production
their broadband performance in contrast to conventional process using hybrid printing techniques that combine
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absorbers that use magnetic materials. The incorporation FDM with direct ink writing or aerosol jet printing.
of magnetic nanoparticles into CFRPs is difficult due By using this method, it would be possible to optimize
to mechanical property degradation, weak interfacial impedance matching across a wide range of frequency
bonding, and nozzle blockage. Furthermore, printability bands by producing graded-index absorbers with spatially
and layer adhesion may be compromised since high filler varied electromagnetic characteristics. Furthermore,
loadings are frequently needed to achieve high electrical the creation of innovative core-shell filament materials
conductivity. The development of hybrid composites, in which CFs are covered in lossy nanomaterials such as
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which combine CFs with conductive or magnetic coatings ferrites or MXenes may improve dielectric and magnetic
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(such as nickel-plated CFs ), may close this gap, although loss mechanisms while preserving printability. These
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processing techniques need to be improved to preserve developments would surmount the present restrictions
structural integrity and print fidelity. 96 in obtaining broadband absorption while maintaining
structural soundness.
Increasing the amount of CF improves EMA but also
causes printed structures to become more brittle and less AM-CFRP absorber design will undergo a revolution
ductile. Layer delamination and poor interlayer adhesion with the combination of computational electromagnetics
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can result from CFRPs’ high stiffness, especially in complex and ML. Physics-informed neural networks can make
geometries, for optimal electromagnetic performance. rapid predictions of ideal fiber alignment patterns, infill
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The final component may also be further weakened densities, and metamaterial geometries suited to specific
by residual strains caused by the thermal expansion absorption bandwidths. To minimize material consumption
mismatch between CFs and polymer matrices during and optimize wave attenuation, generative adversarial
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printing. Particularly for automotive and aerospace networks may suggest new, bio-inspired structures.
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applications where absorbers must sustain structural Real-time performance evaluation throughout the printing
loads, striking a balance between mechanical durability process may be made possible using digital twin technology,
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and electromagnetic efficacy is essential. Future research enabling adaptive manufacturing modifications. By
could investigate graded material designs, improved fiber drastically cutting down on the typical trial-and-error
orientations, or toughened polymer matrices to lessen these development cycle, these AI-powered techniques will
trade-offs without compromising absorption efficiency. speed up the process of finding high-performance
absorber designs that would be impossible to build using
The scalability of AM-CFRP absorbers for industrial traditional methods. Cloud-based design tools may also
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applications is restricted by the high cost of CF-reinforced facilitate collaboration among workers and experts in the
filaments and the difficulty of multimaterial printing. manufacturing, electromagnetics, and material fields in
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The resolution and throughput needed for the large-scale optimization. The emergence of technologies powered by
fabrication of high-performance EMWA structures are electromagnetic fields offers revolutionary possibilities for
difficult for current additive manufacturing techniques. overseeing the production and manufacturing process of
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Furthermore, post-processing procedures such as thermal CFRP and CF. The synthesis, processing, and recycling
annealing or chemical treatments to improve conductivity stages of CFRP can be completed quickly, effectively,
increase manufacturing time and cost. Defects and sustainably with this technology. Figure 9 illustrates
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brought on by the process, such as voids or uneven layer the functions of several novel approaches, which use
bonding, might worsen electromagnetic performance. electromagnetic radiation forms such as electric currents
Developments in in situ curing methods, high-speed and microwaves, in drastically cutting energy use, lessening
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additive manufacturing, and recyclable materials will environmental impact, and improving CFRP performance.
be crucial to overcoming these obstacles. One major The rise of electromagnetic field-driven technologies
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obstacle to broader deployment is the development of presents disruptive opportunities for managing CF and
scalable, affordable production techniques that preserve CFRP manufacturing and production. It offers a rapid,
exact control over electromagnetic characteristics. efficient, and environmentally friendly solution for the
synthesis, processing, and recycling phases. By utilizing
6.2. Future perspectives
electromagnetic radiation forms such as electric currents
Future developments in multimaterial additive and microwaves, these innovative approaches hold
manufacturing will witness the seamless integration of promise for significantly reducing energy consumption
multifunctional components into CFRP constructions. and lowering environmental impact.

Volume 1 Issue 2 (2025) 17 doi: 10.36922/ESAM025160008