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.