This study discusses the frictional wear performance of three 3D-printed materials, acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), and high-impact polystyrene (HIPS), while evaluating different layer thickness levels. The materials were subjected to wear volume and rate tests by ball-on-disc wear tests at various thickness levels (0.1, 0.2, and 0.3 mm) and sliding distances. Lastly, SEM analysis was carried out to study the wear tracks and debris developed during the testing. Quantitatively, ABS maintained a mean wear volume below 0.15 mm³ across all test conditions (e.g., 0.05 ± 0.01 mm³ at 0.1 mm layer thickness and 150 m sliding distance), whereas PLA and HIPS recorded much higher averages of 1.5 mm³ and 3.0 mm³, respectively. With the increase in layer thickness, which caused an upward trend in the obtained results, the wear volume of the investigated materials also increased. ABS exhibited the smallest material loss of all three polymers; for example, at 0.1 mm layer thickness and a 150 m sliding distance, the mean wear volume was only 0.05 mm³, and even under the harshest condition tested (0.3 mm layer thickness, 300 m), the value remained below 0.15 mm³. PLA and HIPS showed higher wear volumes, while HIPS had the lowest resistance among the three materials. The multifunctional wear behavior difference contributed by material type was 59.76%, as shown through ANOVA, and that by layer thickness was 21.32%. Among the parameters investigated, material type had the largest control in wear behavior due to inherent variation in the structural characteristics of the material such as interlayer adhesion, toughness, and brittleness. For instance, the amorphous nature of ABS and its good layer adhesion provided significantly superior wear resistance compared to the brittle PLA and the poorly adhered HIPS. It is highlighted in this research that selecting appropriate material and layer thickness combinations can improve the durability of 3D-printed components.

Today, the aim is to reduce the harm caused by vehicles to the environment in accordance with decisions made to address environmental pollution and the global climate crisis. To this end, in addition to design improvements, and technological advancements, materials that can reduce the weight of the vehicles and provide the desired mechanical properties, are being studied. Glass fiber‐polyamide composites offer a unique combination of properties that make them suitable for a wide range of applications in the automotive industry. This study focused on the production of GF‐PA6 composites using compression molding and Tailor Fiber Placement (TFP) technology. The production was carried out at a constant temperature of 300°C, and 16 bar pressure, with holding times of 270–300–330 s. Short‐term thermal aging cycles were also applied to evaluate the effects of environmental exposure on the GF‐PA6 composite material. The wear behavior of the composite was then assessed through sliding wear tests, which indicated that an increase in holding time improved the wear resistance, while the aging process had a negative impact. The experimental results were analyzed statistically using response surface methodology (RSM) and showed a statistically consistent response. It was found that aging had no significant effect on the coefficient of friction (COF), but significantly impacted the wear rate. The COF of composite samples decreased approximately 35% with increasing holding time. When the sliding distance increased from 150 to 300 m, the wear rate value decreased by 24% in non‐aged samples and by 35% in aged samples.