Recently, 3D printing of fiber-reinforced composites has gained significant research attention. However, commercial utilization is limited by the low fiber content and poor fiber–resin interface. Herein, a novel 3D printing process to fabricate continuous fiber-reinforced thermosetting polymer composites (CFRTPCs) is proposed. In brief, the proposed process is based on the viscosity–temperature characteristics of the thermosetting epoxy resin (E-20). First, the desired 3D printing filament was prepared by impregnating a 3K carbon fiber with a thermosetting matrix at 130 °C. The adhesion and support required during printing were then provided by melting the resin into a viscous state in the heating head and rapidly cooling after pulling out from the printing nozzle. Finally, a powder compression post-curing method was used to accomplish the cross-linking reaction and shape preservation. Furthermore, the 3D-printed CFRTPCs exhibited a tensile strength and tensile modulus of 1476.11 MPa and 100.28 GPa, respectively, a flexural strength and flexural modulus of 858.05 MPa and 71.95 GPa, respectively, and an interlaminar shear strength of 48.75 MPa. Owing to its high performance and low concentration of defects, the proposed printing technique shows promise in further utilization and industrialization of 3D printing for different applications.
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