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<p>Growing demand for sustainable and high-performance materials has driven interest in hybrid natural fiber-reinforced composites incorporating bio-fillers and engineered reinforcements. In this study, hybrid polyester-based composites reinforced with Kaycha Piece Dried (PD) fiber, a 3D-printed ABS mesh, and walnut shell-derived biocarbon were fabricated and evaluated. The composites are compared with the unfilled hybrid composite (PFB0), consisting of 20 wt. % Kaycha PD fiber and 20 wt. % ABS mesh without biocarbon filler. Among all compositions, specimen PFB2 (3 wt. % biocarbon) exhibited the most balanced mechanical and fatigue performance. Compared to the unfilled composite (PFB0), PFB2 showed improvements of 21.3% in tensile strength (148&#xa0;MPa), 14.7% in flexural strength (164&#xa0;MPa), 79.4% in impact energy (3.91&#xa0;J), and 2.5% in hardness (81 Shore D). Fatigue life increased by 33.3%, 33.9%, and 38.4% at 25%, 50%, and 75% of ultimate tensile strength, respectively. These enhancements are attributed to uniform biocarbon dispersion, improved interfacial bonding, effective stress transfer, and crack deflection mechanisms without filler agglomeration. In contrast, specimen PFB3 (5 wt. % biocarbon) demonstrated superior long-term performance. It exhibited reductions in creep strain of 20.7%, 15.7%, and 30.3% at 5,000&#xa0;s, 10,000&#xa0;s, and 15,000&#xa0;s, respectively, along with a 23.5% decrease in water absorption (1.24%) compared to PFB0. This behavior is associated with increased matrix rigidity, restricted polymer chain mobility, efficient void filling, and the development of tortuous diffusion pathways that limit moisture ingress. Overall, the results demonstrate a strong synergistic effect between Kaycha PD fiber, ABS mesh, and biocarbon filler. Optimizing filler content is critical for achieving a balance between mechanical performance and environmental durability in sustainable hybrid composites.</p>

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Load bearing investigations on novel ABS-biocarbon printed core/hybrid Kaycha PD fiber polyester sandwich composite for structural applications

  • 期刊论文

  • 发表日期：

    2026年5月29日

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  • Ravikiran chintalapudi,
  • Aman sharma,
  • P. Maria Antony Sebastin Vimalan,
  • D. R. Srinivasan,
  • Dhandapany sendil kumar

摘要

Growing demand for sustainable and high-performance materials has driven interest in hybrid natural fiber-reinforced composites incorporating bio-fillers and engineered reinforcements. In this study, hybrid polyester-based composites reinforced with Kaycha Piece Dried (PD) fiber, a 3D-printed ABS mesh, and walnut shell-derived biocarbon were fabricated and evaluated. The composites are compared with the unfilled hybrid composite (PFB0), consisting of 20 wt. % Kaycha PD fiber and 20 wt. % ABS mesh without biocarbon filler. Among all compositions, specimen PFB2 (3 wt. % biocarbon) exhibited the most balanced mechanical and fatigue performance. Compared to the unfilled composite (PFB0), PFB2 showed improvements of 21.3% in tensile strength (148 MPa), 14.7% in flexural strength (164 MPa), 79.4% in impact energy (3.91 J), and 2.5% in hardness (81 Shore D). Fatigue life increased by 33.3%, 33.9%, and 38.4% at 25%, 50%, and 75% of ultimate tensile strength, respectively. These enhancements are attributed to uniform biocarbon dispersion, improved interfacial bonding, effective stress transfer, and crack deflection mechanisms without filler agglomeration. In contrast, specimen PFB3 (5 wt. % biocarbon) demonstrated superior long-term performance. It exhibited reductions in creep strain of 20.7%, 15.7%, and 30.3% at 5,000 s, 10,000 s, and 15,000 s, respectively, along with a 23.5% decrease in water absorption (1.24%) compared to PFB0. This behavior is associated with increased matrix rigidity, restricted polymer chain mobility, efficient void filling, and the development of tortuous diffusion pathways that limit moisture ingress. Overall, the results demonstrate a strong synergistic effect between Kaycha PD fiber, ABS mesh, and biocarbon filler. Optimizing filler content is critical for achieving a balance between mechanical performance and environmental durability in sustainable hybrid composites.