Continuous fiber cellular structures: a state-of-the-art review on structural design, optimization, applications and future challenges

Continuous Fiber Cellular Structures (CFCS)s represent a significant advancement in material science and engineering, characterized by their lightweight configurations and tailorable properties. These structures are increasingly leveraged across various industries, including aerospace, automotive, and biomedical sectors, owing to their superior mechanical properties, such as high strength-to-weight ratios and exceptional energy absorption capabilities. However, issues such as the manufacturing complexity, cost-effectiveness, and durability of these structures under varying environmental conditions continue to pose significant challenges. Furthermore, the integration of CFCSs into existing manufacturing processes demands innovative solutions to overcome the technological limitations associated with their production and application. This review provides a comprehensive insight into the current state of continuous fiber cellular structures, focusing on the structural design methodologies and optimizations that underpin their development, their applications across different industries, and the technological challenges that must be addressed to realize their potential fully. This paper also identifies the core directions for guiding the future development of CFCSs technology, offering novel perspectives and transformative ideas to drive the continued advancement of the field.