These day’s auto manufacturers are turning towards the usage of lightweight materials to increase the product lifetime, durability, energy efficiency, strength and stiffness. Commonly Fused deposition modeling (FDM) machine technology is used for making light-weight and high-strength parts. The parts manufactured by FDM process can achieve high accuracy and precision in less time compared to other 3D printing methods. Acrylonitrile Butadiene Styrene (ABS), Poly lactic acid (PLA), High impact polystyrene (HIPS), Nylon Carbon Fiber (CF) etc. are the materials used in FDM process. Adding one material to another material may change the material properties which can be used for lightweight materials at high strength. In this experiment Nylon CF and ABS are prepared by sandwich structure which may influence the mechanical properties. This experiment shows us better results than pure ABS material. May be one layer of CF can change the mechanical properties of ABS than using pure ABS which results in strength and cost of the material. In this experimental study, Taguchi orthogonal array L18 with a three-factor design is used for design of experiments. We considered build orientations of material as 0°, 45° and 60° and infill densities as 100%, 80% and 60% as varying parameters during FDM process. This study aims to determine the optimal parameters for tensile and flexural loadings. Following the ASTM standards for tensile and flexural tests, specimens of ABS and CF are prepared separately by FDM process. These specimens are combined with the hand layup process by using epoxy resin to achieve the desired sandwich structures (18 Tensile, 18 Flexural specimens). As per experimental results observed that tensile testing 75%CF and 25%ABS (Sandwich structure) with 60° orientation and 60% infill density and for flexural testing same sandwich structure with 45° orientation and 80% infill density given better results than pure ABS. The results are validated by ANOVA analysis.