This state-of-the-art innovatory overview essentially debates practical worth of three-dimensional printed composites/nanocomposites (especially carbon fiber designs) for aerospace sector. Recently, three-dimensional printing (additive manufacturing) has competently transpired for designing high performance space structures. The manuscript systematically frameworks fundamentals of three-dimensional printing approach, ensuing high-tech aeronautical carbon fiber composites/nanocomposite systems, and space components/structural applications. Amongst carbonaceous fillers, short/continuous carbon fibers were inspected as outperforming reinforcements for aerospace. Additionally, surface modified/composited carbon fibers with nanocarbons (carbon nanotube, graphene) have been reported. Accordingly, polyamide, poly(lactic acid), poly(ether ether ketone), epoxies, etc. have been documented as substantial thermoplastic/thermosetting matrices. Ensuing radical polymer/carbon fiber or polymer/carbon fiber/nanocarbon hybrids have benefits regarding low-cost manufacturing, structural precision, complex geometries, high efficiency, least structural defects/voids, superior tensile and shear strength/modulus, compression strength, interlaminar strength, wear properties, thermo-dimensional constancy, and heat stability features, under extreme space environments. Consequently, cutting-edge three-dimensional printed carbon fiber hybrids offered myriad of promising opportunities for mechanically robust (nozzle wearing, strengthened wing spar/ribs, resilient rotating components, interlaminar strength/dimensional stability) and high temperature stable (cryogenic fuel storage, lower earth orbital stability, thermal-dimensional steadiness, thermal conductivity) for aerospace modules. Henceforth, three-dimensional printing owns enormous engineering potential to meet aeronautical manufacturing demands by overcoming challenges of traditional techniques.
