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<p>The increasing demand for sustainable and high performance polymer composites in additive manufacturing has encouraged the use of bio-based reinforcements in engineering thermoplastics. In this investigation, Acrylonitrile Butadiene Styrene (ABS) was reinforced with varying volume fractions (1–5%) of alkali-silane treated biosilica particles derived from sugarcane bagasse to develop eco-friendly composites suitable for 3D printing applications. The samples were designated as F (100 vol. % ABS), F1 (99/1), F2 (97/3), and F3 (95/5) according to the ABS/biosilica ratio. Standard test specimens were fabricated using fused filament fabrication (FFF) and subsequently joined by Friction stir wielding (FSW) in accordance with ASTM guidelines. Their mechanical (tensile, flexural, impact and hardness), wear, and flammability behaviours were systematically investigated. Results revealed that the inclusion of treated biosilica significantly enhanced the mechanical and functional performance of ABS. The composite F2 (3 vol. %) exhibited the highest mechanical strength, with a tensile strength of 150&#xa0;MPa, flexural strength of 138&#xa0;MPa, and impact strength of 3.9&#xa0;J, demonstrating a substantial improvement over the neat ABS (F) sample. The improvement is attributed to strong filler-matrix interfacial bonding achieved through silane modification and uniform particle dispersion during 3D printing. In contrast, the F3 composite displayed superior tribological behaviour, wear of 20.82 micron and a coefficient of friction (COF) of 0.31, indicating enhanced surface durability. Similarly, the flammability resistance also improved progressively with biosilica content, measuring lowest flame propagation speed is 5.9&#xa0;mm/min. Scanning electron microscopic (SEM) analysis confirmed homogeneous filler distribution and reduced defects in the printed composites. Overall, the findings demonstrate the alkali-silane treated biosilica effectively enhances the mechanical strength, wear resistance, and flame retardancy of 3D printed ABS composites, making them promising candidates for functional for functional and structural applications in sustainable additive manufacturing.</p>

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Process-property Evaluation of 3D-printed ABS/biosilica Biocomposites Reinforced with Sugarcane Bagasse under Friction Stir Welding

  • 期刊论文

  • 发表日期：

    2026年7月13日

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  • R. Ajish Kumar,
  • M. Felix Xavier Muthu

摘要

The increasing demand for sustainable and high performance polymer composites in additive manufacturing has encouraged the use of bio-based reinforcements in engineering thermoplastics. In this investigation, Acrylonitrile Butadiene Styrene (ABS) was reinforced with varying volume fractions (1–5%) of alkali-silane treated biosilica particles derived from sugarcane bagasse to develop eco-friendly composites suitable for 3D printing applications. The samples were designated as F (100 vol. % ABS), F1 (99/1), F2 (97/3), and F3 (95/5) according to the ABS/biosilica ratio. Standard test specimens were fabricated using fused filament fabrication (FFF) and subsequently joined by Friction stir wielding (FSW) in accordance with ASTM guidelines. Their mechanical (tensile, flexural, impact and hardness), wear, and flammability behaviours were systematically investigated. Results revealed that the inclusion of treated biosilica significantly enhanced the mechanical and functional performance of ABS. The composite F2 (3 vol. %) exhibited the highest mechanical strength, with a tensile strength of 150 MPa, flexural strength of 138 MPa, and impact strength of 3.9 J, demonstrating a substantial improvement over the neat ABS (F) sample. The improvement is attributed to strong filler-matrix interfacial bonding achieved through silane modification and uniform particle dispersion during 3D printing. In contrast, the F3 composite displayed superior tribological behaviour, wear of 20.82 micron and a coefficient of friction (COF) of 0.31, indicating enhanced surface durability. Similarly, the flammability resistance also improved progressively with biosilica content, measuring lowest flame propagation speed is 5.9 mm/min. Scanning electron microscopic (SEM) analysis confirmed homogeneous filler distribution and reduced defects in the printed composites. Overall, the findings demonstrate the alkali-silane treated biosilica effectively enhances the mechanical strength, wear resistance, and flame retardancy of 3D printed ABS composites, making them promising candidates for functional for functional and structural applications in sustainable additive manufacturing.