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<p>Polyamide 6 (nylon 6) is a versatile thermoplastic widely used in additive manufacturing for lightweight structural components. Markforged has developed Onyx, a micro carbon fiber-filled nylon that is strong, tough, and chemically resistant. Its Mark Two system can fabricate Onyx parts reinforced with continuous carbon fibers to further enhance mechanical performance. However, nylon composites produced by fused filament fabrication (FFF) typically suffer from high porosity and poor interlayer bonding, which limit their structural efficiency. This study investigates the influence of drying and annealing with compaction on the mechanical properties of 3D-printed Onyx reinforced with six layers of continuous carbon fiber. Dogbone specimens were fabricated at different raster orientations and tested in tension. Post-processing treatments included drying at 70&#xa0;°C and annealing at 171&#xa0;°C under 0.552&#xa0;MPa (80&#xa0;psi) compaction. Compared with untreated parts, drying substantially improved tensile strength and modulus, primarily through void reduction, moisture control, and improved fiber–matrix adhesion. By contrast, annealing with compaction produced mixed outcomes—stiffness gains under certain conditions, but also matrix degradation at high temperature. The observed behavior reflects the combined effects of fiber orientation, porosity, compaction, and crystalline structure. These findings highlight practical post-processing strategies for improving the performance of lightweight polymer composites manufactured by FFF, with relevance to aerospace and automotive applications.</p>

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Effect of Post-Processing on the Mechanical Properties of Carbon Fiber-Reinforced Polyamide Composites Fabricated by Fused Filament Fabrication

  • 期刊论文

  • 发表日期：

    2026年7月14日

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  • Hamid EisaZadeh,
  • Thienan Le,
  • Patrick McCarthy

摘要

Polyamide 6 (nylon 6) is a versatile thermoplastic widely used in additive manufacturing for lightweight structural components. Markforged has developed Onyx, a micro carbon fiber-filled nylon that is strong, tough, and chemically resistant. Its Mark Two system can fabricate Onyx parts reinforced with continuous carbon fibers to further enhance mechanical performance. However, nylon composites produced by fused filament fabrication (FFF) typically suffer from high porosity and poor interlayer bonding, which limit their structural efficiency. This study investigates the influence of drying and annealing with compaction on the mechanical properties of 3D-printed Onyx reinforced with six layers of continuous carbon fiber. Dogbone specimens were fabricated at different raster orientations and tested in tension. Post-processing treatments included drying at 70 °C and annealing at 171 °C under 0.552 MPa (80 psi) compaction. Compared with untreated parts, drying substantially improved tensile strength and modulus, primarily through void reduction, moisture control, and improved fiber–matrix adhesion. By contrast, annealing with compaction produced mixed outcomes—stiffness gains under certain conditions, but also matrix degradation at high temperature. The observed behavior reflects the combined effects of fiber orientation, porosity, compaction, and crystalline structure. These findings highlight practical post-processing strategies for improving the performance of lightweight polymer composites manufactured by FFF, with relevance to aerospace and automotive applications.