Direct printing of carbon fiber reinforced thermoplastic plastic on metal sheets via fused deposition modeling assisted by laser texturing

Abstract Printing polymers on metal surfaces using fused deposition modeling could enhance the versatility of hybrid structures. However, the differences between metals and plastics prevented the effective spreading of molten plastic on metal surfaces, challenging reliable plastic printing on metal substrates. This study employed a nanosecond laser to fabricate laser‐textured grids of varying widths (0.2–0.5 mm) on a 6061 aluminum alloy (6061Al) surface. Carbon fiber reinforced thermoplastic plastic (CFRTP) was printed on 6061Al surface in different printing directions (0°, 45°, and 90°). The influence of laser texturing and printing direction on joint performance was evaluated. The findings indicated the laser‐texturing increased 6061Al surface roughness, enhancing wettability of CFRTP on 6061Al surface. The 45° printing direction provided the best wetting, resulting in a tensile‐shear force of 1631.7 N, 218% higher than at 90°. Optimal performance was achieved with a 0.5‐mm texture width, increasing tensile‐shear force by 180% compared to 0.2 mm and 67% compared to 0.6 mm. Interfacial stress concentration decreased and then increased with the increase of laser‐textured width and the 45° printing direction provided the longest print path and best resin spreading. This research presented a novel approach to metal‐polymer joining, with significant implications for advanced lightweight hybrid structures. Highlights Printing carbon fiber reinforced thermoplastic plastic (CFRTP) on 6061 aluminum alloy (6061Al) surface was achieved by fused deposition modeling via laser texturing. The print direction affected the wetting and spreading space of the molten resin. Pinning effect of printed CFRTP/6061Al by laser texturing was studied. The spreading and wetting of resin determined the mechanical properties.