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With the high precision requirements and the trend of large-scale composite parts, the development of composite molds is imminent. The short carbon fiber (SCF) composite mold is mainly prepared by the technological process flow of composite sheet injection, the bonding of composite plates, and machining. However, the current process optimization method has not matured adequately, and there are still many shortcomings, for example, low precision and high cost. In this paper, the optimization method of SCF/polyetherimide (PEI) composite molds is proposed. Many experiments have been conducted, and the results show that the coefficient of thermal expansion of composite samples can be effectively reduced and the mechanical properties can be improved by optimizing the SCF weight ratio and carbon fiber length. The bonding strength of composite joints in a high-temperature environment can be improved by optimizing the bonding process parameters and modification by carbon nanotubes. Based on the above optimization method, the SCF/PEI composite mold is prepared, and the C-shaped beam composite part is fabricated by using this mold. Compared with the part made by aluminum mold, the shape accuracy of the C-shaped beam composite part is proven high through digital measurement technology. [ABSTRACT FROM AUTHOR]

The inherent defects of the layer‐by‐layer manufacturing process limit the mechanical performance of 3D‐printed composite parts. This paper explores a process optimization method for continuous fiber composites 3D printing to improve the mechanical performance of 3D‐printed CF/PA6 (Carbon Fiber/Nylon 6) parts. First, the effects of printing temperature, printing speed, layer thickness, and side step on the mechanical performance of 3D‐printed CF/PA6 were studied by conducting variable parameter printing experiments. All optimal printing parameters for CF/PA6 were obtained, and their impact mechanisms were analyzed. Second, the coupling effect of temperature and pressure of post‐processing reduced the internal voids of 3D‐printed CF/PA6 and improved its mechanical properties. The influence mechanism of the coupling effect of temperature and pressure was summarized, and the optimal post‐processing parameters applicable to CF/PA6 were obtained. Based on the above process optimization, the fiber volume content of the printed CF/PA6 reached 41.05%, and the bending strength and elastic modulus reached 651.54 MPa and 79.08 GPa, which were 209.05% and 179.53% higher than those before optimization. Moreover, the tensile strength and elastic modulus reached 730 MPa and 29.23GPa, which were 98.10% and 81.10% higher than those before optimization. The experimental results give a positive validation of the effectiveness and feasibility of the proposed methodology. Highlights: The effects of printing temperature, printing speed, layer thickness, and side step on the mechanical properties of 3D‐printed CF/PA6 were investigated. The optimal printing parameters applicable to CF/PA6 were obtained and their influence mechanisms were analyzed.The effects of the heat press processing method on the internal voids and mechanical properties of 3D‐printed CF/PA6 were investigated, and the optimal post‐processing parameters applicable to CF/PA6 were obtained.The study resulted in optimal printing parameters and post‐processing parameters for 3D printing CF/PA6, which greatly enhanced its tensile and flexural strength and modulus. [ABSTRACT FROM AUTHOR]