Impact of Infill Density and Glass Fiber Reinforcement on the Compressive and Bending Strength of Acrylonitrile Butadiene 3D‐Printed Corrugated Sandwich Panels

Sandwich panel structures are widely utilized across various industries due to their exceptional strength‐to‐weight ratios, particularly when employing a corrugated core. In this study, the innovative use of additive manufacturing and fused deposition modeling to produce corrugated core sandwich panels with enhanced mechanical properties are investigated. Acrylonitrile butadiene styrene filaments reinforced with varying percentages of glass fibers (0, 5, 10, and 15%) are utilized, and three distinct infill density patterns are examined. The panels are subjected to three‐point bending and compressive tests, revealing that a 10% glass fiber reinforcement yields the highest bending (1973.62 N) and compressive strengths (9581.56 N). Beyond this reinforcement level, strength decreases due to fiber agglomeration. Microstructural analysis using scanning electron microscope confirms optimal dispersion and bonding of glass fibers at 10%, which improves mechanical performance. Thermal analysis identified the appropriate printing temperatures, ensuring high‐quality layer adhesion. The novel approach of varying infill densities and fiber content contributes to optimizing 3D printing parameters, advancing the production of lightweight, high‐strength structures for applications in automotive, aerospace, and construction industries. In this study, significant insights into the relationship between material composition, manufacturing parameters, and mechanical properties of 3D‐printed sandwich panels are provided.