Recently, continuous fibre reinforcement has been combined with three-dimensional (3D) printing to create stiffer printed components. This study investigates the effect of wire volume fraction, type of polymer matrix, and wire treatment on the flexural properties of 3D printed continuous wire polymer composites (CWPCs) through a design of experiment study. CWPC samples were printed using a modified, open-source 3D printer. The flexural properties were measured and compared to non-reinforced samples. An analytical model was developed to describe the stress distribution across unidirectional CWPCs as a function of the geometrical printing parameters, reinforcement dimensions, and material properties. Sample failure analysis was performed to investigate failure modes and offer insight into further enhancement of the composite's properties.
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