METHOD OF FORMING COMPOSITE FEEDSTOCK STRIPS FOR ADDITIVE MANUFACTURING

Provided are composite feedstock strips for additive manufacturing and methods of forming such strips. A composite feedstock strip may include continuous unidirectional fibers extending parallel to each other and to the principal axis of the strip. This fiber continuity yields superior mechanical properties, such as the tensile strength along strip's principal axis. Composite feedstock strips may be fabricated by slitting a composite laminate in a direction parallel to the fibers. In some embodiments, the cross-sectional shape of the slit strips may be changed by reattributing material at least on the surface of the strips and/or by coating the slit strips with another material. This cross-sectional shape change may be performed without disturbing the continuous fibers within the strips. The cross-sectional distribution of fibers within the strips may be uneven with higher concentration of fibers near the principal axis of the strips, for example, to assist with additive manufacturing.