An innovative hybrid additive manufacturing method for carbon fiber-reinforced polyetheretherketone-polyetheretherketone (CF/PEEK-PEEK) has been proposed, combining laser-assisted automated fiber placement (LAFP) and fused filament fabrication (FFF) processes. The study examined shear resistance characteristics of CF/PEEK-PEEK samples under varying process variables, including compaction force, layup rate, and radiant power. The highest shear strength, measured at 52.70 ± 0.77 MPa, was achieved using a radiant power setting of 150 W, combined with a compaction force of 220 N and a layup rate of 40 mm/s. The failure behavior of CF/PEEK-PEEK composites was studied through digital image correlation (DIC), which allowed for monitoring the evolution of cracks. In addition, the interface fusion effect was indicated by computed tomography (CT) and the porosity distribution within the CF/PEEK-PEEK was observed. A minimum volume porosity of 0.25% was achieved. And the successful fabrication of a CF/PEEK-PEEK case demonstrated the viability and dependability of the novel hybrid additive manufacturing method.
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