3D printing of acrylonitrile butadiene styrene/continuous glass fiber composite by fused deposition modeling; process window and governing mechanisms

Purpose Although several researchers have obtained different procedures for continuous fiber composite FDM 3D printing, addressing issues such as low print speed and inaccurate fiber alignment spotlights the necessity of a comprehensive study on the phenomena happening in the process. This study aims to reveal the influence of print parameters, including print speed, nozzle diameter and layer height, on the integrity and quality of 3D-printed ABS/E-glass composites. Design/methodology/approach In the first step, visual inspection was conducted on the single-layer 3D-printed parts, and a general overview of the influence of each parameter was observed. Then, the behavior of fibers influenced by the variation of print parameters was evaluated more precisely using the burn-off test. Finally, the observations were validated by mechanical tests and microscopic evaluations. Findings The results revealed the destructive effect of increasing print speed and decreasing layer height on the fiber/matrix impregnation and causing fiber damage and warpage. Moreover, it was concluded from the mechanical and microscopic analyses that fiber alignment and embedment can be effectively controlled by selecting suitable print settings so that the tensile modulus of 3D-printed composites improved up to 26.4% by aligning the fibers using the proper print settings. Originality/value The findings of this research enlighten users on feasible approaches to improve the quality of 3D-printed parts. Moreover, they are capable of being exploited for further investigations on the parts’ mechanical properties as well as the process efficiency.