This experimental study investigates the mechanical properties of polymer matrix composites containing nanofiller developed by fused deposition modelling (FDM). A novel polymer nanocomposite was developed by amalgamating polycarbonate-acrylonitrile butadiene styrene (PC-ABS) by blending with graphene nanoparticles in the following proportions: 0.2, 0.4, 0.6, and 0.8 wt %. The composite filaments were developed using a twin-screw extrusion method. The mechanical properties such as tensile strength, low-velocity impact strength, and surface roughness of pure PC-ABS and PC-ABS + graphene were compared. It was observed that with the addition of graphene, tensile strength and impact strength improved, and a reduction in surface roughness was observed along the build direction. These properties were analyzed to understand the dispersion of graphene in the PC-ABS matrix and its effects on the parameters of the study. With the 0.8 wt % addition of graphene to PC-ABS, the tensile strength increased by 57%, and the impact resistance increased by 87%. A reduction in surface roughness was noted for every incremental addition of graphene to PC-ABS. The highest decrement was seen for the 0.8 wt % addition of graphene reinforcement that amounted to 40% compared to PC-ABS.

In this study, acrylonitrile butadiene styrene (ABS) and graphite powder—a solid lubricant—were filled and characterized for friction and wear responses. The fused deposition modeling (FDM) technique was utilized to synthesize ABS–graphite composites. A twin-screw extrusion approach was employed to create the composite filament of graphite–ABS that is suitable for the FDM process. Three graphite particle ratios ranging from 0% to 5% were explored in the ABS matrix. The wear and friction properties of ABS composites were examined using a pin on disc tribometer at varied sliding velocities and weights. As a result of the graphite addition in the ABS matrix, weight losses for FDM components as well as a decreased coefficient of friction were demonstrated. Furthermore, as the graphite weight percentage in the ABS matrix grows the value of friction and wear loss decreases. The wear mechanisms in graphite filled ABS composites and ABS were extensively examined using scanning electron microscopy and confocal microscopy.

One of the most promising and widely used additive manufacturing technologies, fused deposition modelling (FDM), is based on material extrusion and is most commonly used for producing thermoplastic parts for functional applications with the objectives of low cost, minimal waste and ease of material conversion. Considering that pure thermoplastic materials have a significantly poor mechanical performance, it is necessary to enhance the mechanical properties of thermoplastic parts generated using FDM technology. One of the conceivable techniques is to incorporate reinforcing materials such as short glass fibre (SGF) into the thermoplastic matrix in order to produce a polymer composite that can be used in engineering applications, such as structural applications. The morphological and mechanical properties of SGF (short glass fibre) reinforced ABS- (Acrylonitrile Butadiene Styrene) based polymer composites created via the method of FDM (fused deposition modelling) were investigated in this work. Properties were evaluated at three different weight percentages (0, 15 and 30 wt%). The composite filaments were developed using the process of twin screw extrusion. The comparison was made between ABS + SGF (short glass fibre) composites and pure ABS of mechanical properties that include surface roughness, tensile strength and low-velocity impact. The tests were carried out to analyze the properties as per ASTM standards. It has been found that the impact strength and tensile strength show an improvement in glass fibre inclusion; moreover, alongside the direction of build, the surface roughness had been reduced. The studies also focused on studying the dispersion characters of SGF in ABS matrix and its impact on the properties. Strength and modulus of SGF reinforced ABS composite has been significantly improved along with reduction of ductility. A 57% increase in tensile strength has been noted for 30 wt% addition of SGF to ABS in comparison to pure ABS. It was also interesting to note the reduction in surface roughness with every incremental addition of SGF to ABS. A 40% reduction in surface roughness has been observed with a 30 wt% addition of SGF to ABS in comparison to pure ABS.

Fused deposition modeling (FDM), one of the most widely used additive manufacturing (AM) processes, is used for fabrication of 3D models from computer-aided design data using various materials for a wide scope of applications. The principle of FDM or, in general, AM plays an important role in minimizing the ill effects of manufacturing on the environment. Among the various available reinforcements, short glass fiber (SGF), one of the strong reinforcement materials available, is used as a reinforcement in the acrylonitrile butadiene styrene (ABS) matrix. At the outset, very limited research has been carried out till date in the analysis of the impact and flexural strength of the SGF-reinforced ABS polymer composite developed by the FDM process. In this regard, the present research investigates the impact and flexural strength of SGF-ABS polymer composites by the addition of 15 and 30 wt % SGF to ABS. The tests were conducted as per ASTM standards. Increments in flexural and impact properties were observed with the addition of SGF to ABS. The increment of 42% in impact strength was noted for the addition of 15 wt % SGF and 54% increase with the addition of 30 wt % SGF. On similar lines, flexural properties also showed improved values of 44 and 59% for the addition of 15 and 30 wt % SGF to ABS. SGF addition greatly enhanced the properties of flexural and impact strength and has paved the path for the exploration of varied values of reinforcement into the matrix.

This paper focuses on the development of copper filled Acrylonitrile Butadiene Styrene (ABS) composites by fused deposition modelling (FDM) and to characterize its friction and wear behaviour. Twin screw extrusion technique was employed to extract copper-ABS composite filament. Three different materials were tested, i.e. pure ABS, ABS+2.5wt% Cu and ABS+5wt% Cu. Friction and wear characteristics of pure ABS and copper filled ABS composites were tested under various loads and sliding velocities. Addition of Copper powder has significantly improved the friction and wear properties of the developed composites. Further, it is also observed that friction and wear behaviour increased with increase in copper content in ABS. Worn out surfaces were subjected to scanning electron microscopy studies to analyse and identify the possible wear mechanisms involved.