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<p>The increasing demand for lightweight and high-performance materials has intensified interest in fibre-reinforced polymer composites for Additive Manufacturing (AM). While fibrous reinforcement can significantly enhance the mechanical properties of 3D-printed parts, poor interfacial bonding between fibres and the thermoplastic matrix remains a major limitation. To address this challenge, this work presents a novel hybrid fabrication approach that combines fused filament fabrication (FFF) of acrylonitrile butadiene styrene (ABS) with the hand lay-up of glass fibre fabric using a solvent-based impregnation technique. An ABS/acetone paste (40 wt% ABS) was optimized to ensure effective fibre wetting and compatibility with the printed substrate. The resulting composites exhibited substantial improvements in tensile performance: the four-layer configuration achieved a 238% increase in tensile strength (105.01 ± 6.61&#xa0;MPa) and a 161% rise in Young’s modulus (5.68 ± 0.47GPa) compared to neat ABS (31.03 ± 0.11&#xa0;MPa and 2.18 ± 0.05 GPa). However, a significant reduction in strain at failure (89–92%) was observed due to the inherent brittleness of glass fibres. Flexural behavior showed a distinct trend, with peak performance occurring at two or three layers, yielding increases of 79% in flexural strength and 350% in stiffness, while flexural strain improved by up to 53%. Beyond this, additional layers led to diminishing returns attributed to fibre buckling under compression. These results demonstrate that the solvent-impregnation method enables superior interfacial adhesion and stress transfer compared to conventional adhesive-based lamination, offering a scalable and effective strategy to produce high-performance, geometrically complex fibre-reinforced AM components for structural applications.</p>

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Enhancement of the mechanical properties of additive manufactured polymeric materials through glass fibre fabric reinforcement and ABS/Acetone paste

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Daniel Kioshi Kawasaki Cavalcanti,
  • Natalia Victoria dos Santos,
  • Henrique Fernandes Medeiros de Queiroz,
  • Jorge de Souza e Silva Neto,
  • Mariana Doina Banea

摘要

The increasing demand for lightweight and high-performance materials has intensified interest in fibre-reinforced polymer composites for Additive Manufacturing (AM). While fibrous reinforcement can significantly enhance the mechanical properties of 3D-printed parts, poor interfacial bonding between fibres and the thermoplastic matrix remains a major limitation. To address this challenge, this work presents a novel hybrid fabrication approach that combines fused filament fabrication (FFF) of acrylonitrile butadiene styrene (ABS) with the hand lay-up of glass fibre fabric using a solvent-based impregnation technique. An ABS/acetone paste (40 wt% ABS) was optimized to ensure effective fibre wetting and compatibility with the printed substrate. The resulting composites exhibited substantial improvements in tensile performance: the four-layer configuration achieved a 238% increase in tensile strength (105.01 ± 6.61 MPa) and a 161% rise in Young’s modulus (5.68 ± 0.47GPa) compared to neat ABS (31.03 ± 0.11 MPa and 2.18 ± 0.05 GPa). However, a significant reduction in strain at failure (89–92%) was observed due to the inherent brittleness of glass fibres. Flexural behavior showed a distinct trend, with peak performance occurring at two or three layers, yielding increases of 79% in flexural strength and 350% in stiffness, while flexural strain improved by up to 53%. Beyond this, additional layers led to diminishing returns attributed to fibre buckling under compression. These results demonstrate that the solvent-impregnation method enables superior interfacial adhesion and stress transfer compared to conventional adhesive-based lamination, offering a scalable and effective strategy to produce high-performance, geometrically complex fibre-reinforced AM components for structural applications.