Enhancing Compressive and Crush Performance of 3D‐Printed ABS Thin‐Walled Tubes Through Glass Fiber Reinforcement and Polyurethane Foam Infusion

This study introduces a novel approach to enhancing the mechanical performance of 3D‐printed acrylonitrile butadiene styrene (ABS) thin‐walled circular tubes by incorporating varying percentages of glass fibers and filling them with different types of polyurethane (PU) foam. Leveraging fused filament fabrication (FFF), the tubes were reinforced with glass fibers (0%, 5%, 10%, and 15%) and injected with soft, semisoft, and rigid PU foams to assess their impact on compressive strength and crush behavior. The experimental results revealed significant improvements in both failure force and energy absorption with the addition of glass fibers and PU foam. Notably, increasing the glass fiber content to 10% transformed brittle failure into a more ductile behavior, while the inclusion of PU foam further elevated the structural strength. The optimal configuration, comprising 10% glass fiber and rigid PU foam, achieved a remarkable compressive force of 3232.61 N and crushing resistance of 755.52 N. Conversely, the weakest performance was observed in samples with 15% glass fiber and no PU foam, underscoring the critical balance between reinforcement and material composition. Crucially, SEM analysis provided insights into the microstructural behavior of the samples, revealing strong bonding between the glass fibers and ABS matrix, as well as between the PU foam and tube walls. The SEM images also highlighted the transition from brittle to ductile failure modes, particularly in samples with optimal glass fiber content. This research demonstrates that the strategic combination of glass fibers and PU foams, coupled with detailed microstructural analysis, can significantly enhance the structural integrity of 3D‐printed components. These findings pave the way for the development of lightweight, high‐strength materials suitable for demanding applications in aerospace, automotive, and structural engineering.