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<p>FFF offers significant design flexibility but is limited in mechanical performance. This study introduces a multiscale carbon fiber reinforcement strategy to enhance the mechanical properties of FFF-printed Acrylonitrile Butadiene Styrene (ABS) composites. Short (5, 15, and 25 wt%) and continuous carbon fibers were incorporated into the ABS matrix using a novel pre-impregnation process that ensures uniform short-fiber distribution and improves fiber–matrix interfacial bonding, resulting in synergistic reinforcement. Microstructural analysis using optical microscopy and SEM confirmed uniform fiber distribution and effective interfacial bonding. Mechanical tests showed that 15 wt% short fibers deliver the best overall mechanical performance while maintaining process stability. At the filament level, tensile strength rose by 25% (50&#xa0;MPa) compared to neat ABS. For printed parts, adding 15 wt% short fibers resulted in a 23% increase in tensile strength (144&#xa0;MPa), a 26.8% boost in impact resistance (65.89&#xa0;kJ/m<sup>2</sup>), and improvements in interlaminar shear (15.6&#xa0;MPa) and flexural strength (143&#xa0;MPa) over the baseline reinforced with only continuous fibers. These results demonstrate the effectiveness of multiscale carbon fiber reinforcement for producing mechanically robust FFF components.</p>

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Multiscale carbon fiber reinforcement in FFF-printed ABS: a pathway to superior strength and impact resistance

  • 期刊论文

  • 发表日期：

    2026年3月25日

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  • Mohammad Hossein Fahimi,
  • Amir Masoud Rezadoust,
  • Seyed Hassan Jafari,
  • Erfan Rassi,
  • Sina Aghaie

摘要

FFF offers significant design flexibility but is limited in mechanical performance. This study introduces a multiscale carbon fiber reinforcement strategy to enhance the mechanical properties of FFF-printed Acrylonitrile Butadiene Styrene (ABS) composites. Short (5, 15, and 25 wt%) and continuous carbon fibers were incorporated into the ABS matrix using a novel pre-impregnation process that ensures uniform short-fiber distribution and improves fiber–matrix interfacial bonding, resulting in synergistic reinforcement. Microstructural analysis using optical microscopy and SEM confirmed uniform fiber distribution and effective interfacial bonding. Mechanical tests showed that 15 wt% short fibers deliver the best overall mechanical performance while maintaining process stability. At the filament level, tensile strength rose by 25% (50 MPa) compared to neat ABS. For printed parts, adding 15 wt% short fibers resulted in a 23% increase in tensile strength (144 MPa), a 26.8% boost in impact resistance (65.89 kJ/m2), and improvements in interlaminar shear (15.6 MPa) and flexural strength (143 MPa) over the baseline reinforced with only continuous fibers. These results demonstrate the effectiveness of multiscale carbon fiber reinforcement for producing mechanically robust FFF components.