Evaluation of fatigue characteristics of <scp>3D</scp> printed/composites reinforced with carbon fiber using design of experiments

Abstract This study investigates the fatigue characteristics of 3D‐printed composites made from polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS), reinforced with carbon fiber. It involves designing and building a rotating bending fatigue machine, creating standard specimens via FDM, and applying DOE using Taguchi method. Standard specimens are subjected to cyclic loading with a print orientation of 0°, 45°/−45°, and 90°, motor speed and load. Materials such as PLA, ABS, PLA‐CF, and ABS‐CF are tested by maintaining a consistent layer thickness of 0.16 mm and 99.99% infill density while varying stress levels. PLA‐CF outperforms PLA, ABS, and ABS‐CF in fatigue life, with 0° print orientation exhibiting superior fatigue strength. Statistical analysis underscores the significance of print direction, material composition, and stress level. Additionally, the study aims to construct S‐N curves for 3D‐printed PLA/ABS composites with carbon fiber reinforcement, advancing our understanding of mechanical properties and print parameter optimization for enhanced fatigue performance in 3D‐printed composites. Highlights Fatigue characteristics of 3D printed composites made from PLA and ABS, reinforced with carbon fiber investigated. Four polymer composites were used: PLA, ABS, PLA‐CF (short carbon fiber), and ABS‐CF (short carbon fiber). The research focused on the impact of 3D print orientation on fatigue properties, considering print angles of 0°, 45°/−45°, and 90°, alongside adjustable factor like motor speed and load. With a consistent layer thickness of 0.16 mm and 99.99% infill density, the fatigue tests were conducted under stress‐controlled conditions at varying stress levels. Results demonstrate that PLA‐CF specimens exhibit superior fatigue lifetimes compared to PLA, ABS, and ABS‐CF samples.