Structural behaviour of polyethylene terephthalate glycol reinforced with carbon fibre through fused filament fabrication for automotive components

Automotive manufacturers are currently facing a range of significant challenges, including disruptions in the supply chain, heightened concerns about sustainability, and evolving customer demands. One promising solution to these issues is the adoption of fused filament fabrication (FFF), a popular manufacturing method. Numerous aspects affecting FFF have an influence on structural behaviour and become a key factor if such parts are designed for industrial use. This work focuses on polyethylene terephthalate glycol (PETG) specimens reinforced with carbon fibres (CFs), while also considering how nozzle hole diameter and internal filling pattern affect structural behaviour, notably flexural strength, compressive strength and impact behaviour. High-modulus CFs’ reinforcement contributes to the improved structural behaviour of PETG composites. Experimental analysis was used to assess the structural behaviour of CF-PETG specimens. Using statistical analysis of the information acquired from the structural behaviour testing of the specimens, the validity of the experimental investigation was valued. The sample's fracture mechanism was studied using high-end microscopy. The composites’ strengths enhanced from 35.31 to 48.96 MPa for compressive strength, 45.76 to 65.12 MPa for flexural strength and 23.75 to 36.54 kJ/m 2 for impact strength. Tailoring these parameters is crucial for achieving the desired performance and structural characteristics of automotive components. Fused filament fabrication parts surpass the flexibility of traditional moulded components, enhancing resilience in automotive applications.