Magnesium matrix composites are extensively used in automotive and structural applications due to their low density, high strength, and wear-resistant properties. To reach the scope of industry needs, research is carried out regarding enhancing the mechanical and tribological behavior of the magnesium composites by reinforcing the nano-sized reinforcements. In the present work, research has been carried out to enhance the properties of the magnesium AZ91D hybrid composite by reinforcing carbon fibers (CFs) and multi-walled carbon nanotubes (MWCNTs) with varying weight percentages (AZ91D + 0.5% CF’s + 0.5% MWCNT and AZ91D + 0.75% CF’s + 0.75% MWCNT, respectively). The experimental tests were carried out to evaluate the mechanical and tribological behavior of the composites. The test results showed that the addition of CF and MWCNT reinforcements improved the hybrid Mg composite’s hardness, tensile strength, and impact strength compared to the base Mg matrix. The AZ91D + 0.75% CF’s + 0.75% MWCNT hybrid composite showed a 19%, 35%, and 66% increased hardness, tensile strength, and impact strength, respectively, compared to the base Mg AZ91D. The wear test results also showed the improved wear resistance of the Mg composite compared to the base matrix. The enhanced wear resistance of the composite is due to the addition of hard MWCNT and CF reinforcements. The wear rate of the AZ91D + 0.75%CF’s + 0.75% MWCNT composite for a load of 30 N at a sliding distance of 1500 m is lower as compared to the base matrix. The SEM micrographs of the worn surfaces revealed the existence of abrasive wear. The improved mechanical and tribological behavior of the magnesium composite is also due to the homogeneous distribution of the hard reinforcement particles along the grain boundaries.

Fused deposition modelling (FDM) is a popular additive manufacturing (AM) technique for modelling, prototyping, and production. FDM is a technology that creates three-dimensional things directly from three-dimensional CAD data. Layer by layer, thermoplastic material is extruded by a temperature-controlled head. FDM, also known as fused filament fabrication (FFF), is a simple and low-cost method of additive manufacturing that was first introduced in 1989. A thermoplastic filament is fed to a heated nozzle in the FFF process. The material is melted here, and the material is deposited as the nozzle travels layer by layer in the x and y axes along the geometry. FDM has proved beneficial in the medical field to produce more naturalistic models for educational, training, and research reasons, as well as treatment and surgical planning.