Additive Manufacturing of Continuous Fiber Reinforced Thermosetting Composites: Research Progress on Application Challenges, Process Exploration, Material Development, and Performance Tailoring

Continuous fiber reinforced thermosetting composites (CFRTCs) are important structural materials for lightweight and high‐performance applications, but conventional manufacturing routes remain constrained by mold dependence, long processing cycles, and limited freedom in fabricating complex fiber‐reinforced architectures. Additive manufacturing (AM) provides an emerging route for mold‐free fabrication of CFRTC components with locally tailored fiber paths and integrated geometries. Rather than presenting the literature as isolated case studies, this review organizes current progress through a process‐material‐interface‐performance framework. Representative AM routes are compared in terms of fiber delivery, resin impregnation, in situ curing, defect formation, achievable fiber volume fraction, and structural performance. Particular attention is given to unresolved trade‐offs, including printability versus high fiber loading, rapid curing versus impregnation quality, interfacial strengthening versus fiber damage, and laboratory‐scale performance versus industrial reproducibility. By distinguishing AM‐enabled applications from conventional composite applications, this review identifies the major barriers and promising research directions for advancing CFRTCs‐AM toward reliable structural deployment.