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<p>This study explores the mechanical performance and energy absorption characteristics of carbon fiber-reinforced nylon composites made with Fused Deposition Modeling (FDM) for high-velocity impact applications. The Response Surface Methodology (RSM) framework was used to optimize the effects of three important process parameters such as printing speed (40–90&#xa0;mm/sec), bed temperature (80–100&#xa0;°C), and infill density (20–80%) using a Box–Behnken Design (BBD). Mechanical tests, including tensile, flexural, and impact strength, along with energy absorption measurements, were conducted on printed parts with a gyroid infill pattern. Strong model validity was demonstrated by the statistical analysis, as all responses had R<sup>2</sup> values greater than 0.98. The findings showed that infill density had a major impact on mechanical and energy-absorbing characteristics. High infill and bed temperatures along with a moderate printing speed produced the best results. Performance metrics were correctly predicted by regression models, and the relationships between process, structure, and property were depicted by contour plots and perturbations. These results show how well-suited carbon nylon FDM components can be for structural uses where higher impact resistance is essential.</p>

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Energy absorption and mechanical strength prediction of 3D printed carbon nylon composite using box–behnken design

  • 期刊论文

  • 发表日期：

    2026年2月19日

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  • K. G. Ashok,
  • M. Prashanth,
  • K. Thavasilingam,
  • A. Praveen Kumar,
  • K. G. Anbarasu

摘要

This study explores the mechanical performance and energy absorption characteristics of carbon fiber-reinforced nylon composites made with Fused Deposition Modeling (FDM) for high-velocity impact applications. The Response Surface Methodology (RSM) framework was used to optimize the effects of three important process parameters such as printing speed (40–90 mm/sec), bed temperature (80–100 °C), and infill density (20–80%) using a Box–Behnken Design (BBD). Mechanical tests, including tensile, flexural, and impact strength, along with energy absorption measurements, were conducted on printed parts with a gyroid infill pattern. Strong model validity was demonstrated by the statistical analysis, as all responses had R2 values greater than 0.98. The findings showed that infill density had a major impact on mechanical and energy-absorbing characteristics. High infill and bed temperatures along with a moderate printing speed produced the best results. Performance metrics were correctly predicted by regression models, and the relationships between process, structure, and property were depicted by contour plots and perturbations. These results show how well-suited carbon nylon FDM components can be for structural uses where higher impact resistance is essential.