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<p>Fused Deposition Modeling (FDM) is a widely used additive manufacturing technique known for its efficiency in producing complex structures at low cost and with minimal material waste. However, weak interlayer bonding and void formation often limit the mechanical performance of printed parts. This study investigates the influence of short fiber reinforcement (carbon and glass) and raster orientation (0°/90° and 45°/ − 45°) on the mechanical, fracture, and thermal behavior of FDM-printed composites. PLA, PLA-CF, and PLA-GF filaments containing 20 wt% short fibers were examined. Tensile, flexural, and fracture toughness tests (K<sub>IC</sub>, G<sub>IC</sub>, and P<sub>Q</sub>) were conducted in accordance with ASTM standards, along with thermogravimetric analysis (TGA), porosity measurements, and scanning electron microscopy (SEM). PLA showed the highest tensile strength at 45°/ − 45° (50.83&#xa0;MPa), whereas PLA-GF at 0°/90° exhibited the highest flexural strength (17.79&#xa0;MPa). The highest fracture toughness was obtained for PLA-GF (K<sub>IC</sub> = 4.71&#xa0;MPa·m<sup>1/2</sup>, P<sub>Q</sub> = 1186.66 N), while PLA displayed the greatest fracture energy (G<sub>IC</sub> = 10.31&#xa0;kJ/m<sup>2</sup>). Fractographic observations revealed fiber pull-out and interfacial debonding, indicating distinct fiber–matrix adhesion mechanisms. TGA results showed improved thermal stability for PLA-CF, and porosity analysis confirmed a direct correlation between void content and mechanical performance. Overall, the results highlight the combined effect of fiber type, printing orientation, and microstructural integrity on the mechanical reliability of FDM-printed composites, particularly for applications requiring enhanced fracture resistance.</p>

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Influence of short carbon and glass fibers on the mechanical performance, thermal stability, and fracture behavior of FDM-printed composites

  • 期刊论文

  • 发表日期：

    2025年10月16日

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  • Frederico de Castro Magalhães,
  • Andrea Del Pilar Fabra Rivera,
  • Juan Carlos Campos Rubio

摘要

Fused Deposition Modeling (FDM) is a widely used additive manufacturing technique known for its efficiency in producing complex structures at low cost and with minimal material waste. However, weak interlayer bonding and void formation often limit the mechanical performance of printed parts. This study investigates the influence of short fiber reinforcement (carbon and glass) and raster orientation (0°/90° and 45°/ − 45°) on the mechanical, fracture, and thermal behavior of FDM-printed composites. PLA, PLA-CF, and PLA-GF filaments containing 20 wt% short fibers were examined. Tensile, flexural, and fracture toughness tests (KIC, GIC, and PQ) were conducted in accordance with ASTM standards, along with thermogravimetric analysis (TGA), porosity measurements, and scanning electron microscopy (SEM). PLA showed the highest tensile strength at 45°/ − 45° (50.83 MPa), whereas PLA-GF at 0°/90° exhibited the highest flexural strength (17.79 MPa). The highest fracture toughness was obtained for PLA-GF (KIC = 4.71 MPa·m1/2, PQ = 1186.66 N), while PLA displayed the greatest fracture energy (GIC = 10.31 kJ/m2). Fractographic observations revealed fiber pull-out and interfacial debonding, indicating distinct fiber–matrix adhesion mechanisms. TGA results showed improved thermal stability for PLA-CF, and porosity analysis confirmed a direct correlation between void content and mechanical performance. Overall, the results highlight the combined effect of fiber type, printing orientation, and microstructural integrity on the mechanical reliability of FDM-printed composites, particularly for applications requiring enhanced fracture resistance.