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<p>Additive manufacturing, particularly fused filament fabrication (FFF), is increasingly employed for functional parts exposed to outdoor conditions, where environmental durability is a critical concern. This study investigates the influence of natural weathering (sunlight, temperature fluctuations, and moisture) on the mechanical and surface performance of acrylonitrile styrene acrylate (ASA) specimens fabricated via FFF. Over a 12-month outdoor exposure (ASTM G7/G7M-21) in central India, tensile and flexural tests showed only minor strength reductions (≤ 4% in XYZ-BO, ≤ 6% in flexural strength), whereas ZXY-BO tensile specimens exhibited greater degradation (≤ 18%) due to weaker interlayer adhesion. In contrast, impact resistance was improved by 18–22% after aging, attributed to microstructural adaptations. Microscopic examinations revealed mild discoloration and limited microcracking, while surface roughness decreased by ~ 6–7% and hardness remained stable (≤ 1.2% increase). Comparative assessment showed that ASA retained superior resistance to UV-induced degradation compared to ABS, which exhibited significant yellowing, surface cracking, and hardness loss (~ 18%). Multi-criteria optimization (Taguchi–TOPSIS) confirmed that extrusion temperature, layer thickness, and build orientation were dominant parameters, with the optimal condition identified as 255&#xa0;°C, 75&#xa0;mm/s, and 0.14&#xa0;mm LT in XYZ-BO. Overall, the findings confirm ASA’s potential for reliable long-term performance in outdoor applications, such as automotive, aerospace, marine, and protective structures, while highlighting the role of process optimization in enhancing durability.</p>

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Effect of Natural Weathering Conditioning on the Mechanical and Surface Performance of Additively Manufactured Acrylonitrile Styrene Acrylate (ASA) Components

  • 期刊论文

  • 发表日期：

    2026年3月26日

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  • Sagar Kailas Gawali,
  • Prashant Kumar Jain

摘要

Additive manufacturing, particularly fused filament fabrication (FFF), is increasingly employed for functional parts exposed to outdoor conditions, where environmental durability is a critical concern. This study investigates the influence of natural weathering (sunlight, temperature fluctuations, and moisture) on the mechanical and surface performance of acrylonitrile styrene acrylate (ASA) specimens fabricated via FFF. Over a 12-month outdoor exposure (ASTM G7/G7M-21) in central India, tensile and flexural tests showed only minor strength reductions (≤ 4% in XYZ-BO, ≤ 6% in flexural strength), whereas ZXY-BO tensile specimens exhibited greater degradation (≤ 18%) due to weaker interlayer adhesion. In contrast, impact resistance was improved by 18–22% after aging, attributed to microstructural adaptations. Microscopic examinations revealed mild discoloration and limited microcracking, while surface roughness decreased by ~ 6–7% and hardness remained stable (≤ 1.2% increase). Comparative assessment showed that ASA retained superior resistance to UV-induced degradation compared to ABS, which exhibited significant yellowing, surface cracking, and hardness loss (~ 18%). Multi-criteria optimization (Taguchi–TOPSIS) confirmed that extrusion temperature, layer thickness, and build orientation were dominant parameters, with the optimal condition identified as 255 °C, 75 mm/s, and 0.14 mm LT in XYZ-BO. Overall, the findings confirm ASA’s potential for reliable long-term performance in outdoor applications, such as automotive, aerospace, marine, and protective structures, while highlighting the role of process optimization in enhancing durability.