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<p>Additive manufacturing, particularly fused deposition modeling (FDM), has emerged as a transformative technology for fabricating polymer-based composites. Although carbon fiber-reinforced nylon composites (CFRNCs) are widely employed in high-performance engineering applications due to their favorable strength-to-weight ratio and thermal stability, limited research has systematically investigated the relationship between critical FDM processing parameters and the resultant composite properties. This study seeks to address this gap by optimizing FDM parameters to improve the mechanical performance and manufacturing efficiency of 3D-printed CFRNC samples. However, the impact of printing parameters—speed, infill pattern, and extrusion temperature—on the mechanical properties (maximum failure load and elongation at break), build time, and weight of printed composites was evaluated. Using response surface methodology (RSM) and ANOVA, we design experiments to evaluate various configurations: printing speeds, infill patterns, and extrusion temperatures. The FDM input parameters were optimized using the desirability function approach. In addition, the fracture surfaces of the tensile test specimens were evaluated using scanning electron microscope (SEM) images. Results indicate that printing speed significantly affects overall properties, with lower speeds reducing build time but improving part weight and increasing maximum failure load. Conversely, higher extrusion temperatures enhance maximum failure load and elongation at break. SEM images indicate that the carbon fiber-reinforced nylon composite fails through a ductile fracture mechanism. Optimization through Design Expert software achieved a 76% desirability score with a printing speed slightly under 59&#xa0;mm/s, an extrusion temperature of 269&#xa0;°C, and a zig zag infill pattern. This study provides valuable guidelines for enhancing the mechanical performance and efficiency of CFRNCs in FDM 3D printing.</p>

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Enhancing Mechanical Performance and Printing Efficiency of Nylon Reinforced by Carbon Fiber Using Fused Deposition Modeling: A Statistical Approach

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • AbdulRahman Bahaddin Shakir,
  • Fakhir Aziz Rasul Rozhbiany,
  • Gawhar Ibraheem Khidhir

摘要

Additive manufacturing, particularly fused deposition modeling (FDM), has emerged as a transformative technology for fabricating polymer-based composites. Although carbon fiber-reinforced nylon composites (CFRNCs) are widely employed in high-performance engineering applications due to their favorable strength-to-weight ratio and thermal stability, limited research has systematically investigated the relationship between critical FDM processing parameters and the resultant composite properties. This study seeks to address this gap by optimizing FDM parameters to improve the mechanical performance and manufacturing efficiency of 3D-printed CFRNC samples. However, the impact of printing parameters—speed, infill pattern, and extrusion temperature—on the mechanical properties (maximum failure load and elongation at break), build time, and weight of printed composites was evaluated. Using response surface methodology (RSM) and ANOVA, we design experiments to evaluate various configurations: printing speeds, infill patterns, and extrusion temperatures. The FDM input parameters were optimized using the desirability function approach. In addition, the fracture surfaces of the tensile test specimens were evaluated using scanning electron microscope (SEM) images. Results indicate that printing speed significantly affects overall properties, with lower speeds reducing build time but improving part weight and increasing maximum failure load. Conversely, higher extrusion temperatures enhance maximum failure load and elongation at break. SEM images indicate that the carbon fiber-reinforced nylon composite fails through a ductile fracture mechanism. Optimization through Design Expert software achieved a 76% desirability score with a printing speed slightly under 59 mm/s, an extrusion temperature of 269 °C, and a zig zag infill pattern. This study provides valuable guidelines for enhancing the mechanical performance and efficiency of CFRNCs in FDM 3D printing.