Optimisation of process parameters for 3D-printed ABS/10% carbon fibre composite: Morphology and mechanical property analysis

This research focuses on optimising process parameters for fabricating 3D-printed acrylonitrile butadiene styrene (ABS) composites reinforced with 10% carbon fibre (CF) to improve their mechanical properties and surface morphology for engineering applications. The investigation considered four key process parameters – printing speed, layer thickness, raster angle and infill pattern – analysed through the Taguchi method and Grey Relational Analysis (GRA). A design of experiments (DOE) approach using an L27 orthogonal array was used to identify the best combination of parameters. Mechanical tests, including tensile, compressive, flexural, impact and hardness evaluations, along with surface roughness measurements, were conducted according to ASTM standards. The results showed significant enhancements in tensile, flexural, and compressive strength, as well as Shore D hardness, for 10% CF-ABS composites compared to pure ABS. The optimised parameters reduced surface roughness from 30 to 25 µm and increased tensile strength from 56 to 61 MPa. Similarly, flexural strength increased from 83 to 86 MPa, compressive strength improved from 53 to 57 MPa, and impact strength increased from 18 to 21 J. Shore D hardness also improved, rising from 68 to 75. Field Emission Scanning Electron Microscopy (FESEM) of the fracture surfaces revealed mechanisms such as fibre pull-out, delamination and fibrillation, indicating improved fibre-matrix bonding. Among the process parameters, pattern type and layer thickness were found to be critical in enhancing mechanical performance. The Gyroid infill pattern exhibited the best overall results. This study provides valuable insights into optimising Fused Filament Fabrication (FFF) 3D printing parameters for producing high-performance composite components, encouraging their wider use in general engineering sectors.