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<p>In this work, a novel hybrid filament structure that combines polyethylene terephthalate glycol (PETG) and acrylonitrile butadiene styrene plus (ABS PLUS) is developed to evaluate the mechanical performance for aeronautical support applications. This study’s main contribution is the examination of the impact, flexural, and tensile characteristics of multi-material specimens made with the fused filament fabrication (FFF) method. To maximize mechanical performance, different combinations of layer thickness, infill density, and printing speed were investigated. The highest ultimate tensile strength was demonstrated by Specimen 6, which was printed at 40&#xa0;mm/s, 0.15&#xa0;mm layer thickness, and 45% infill density. The highest flexural strength was demonstrated by specimen 4, which had a 0.15&#xa0;mm layer thickness, a 15% infill density, and a 60&#xa0;mm/s speed. The highest impact strength was noted in Specimens 6 and 7, which were printed at 60&#xa0;mm/s and 80&#xa0;mm/s, respectively, with 0.15 and 0.2&#xa0;mm layer thicknesses and 15% infill densities. Interestingly, the hybrid structure’s maximum tensile strength (36.5&#xa0;N/mm² in Specimen 9) was much higher than the usual values for ABS (20–30&#xa0;N/mm²) and regular PETG (20–25&#xa0;N/mm²), indicating the synergistic increase made possible by ABS PLUS–PETG hybrid stacking. The potential of this hybrid material system for lightweight, load-bearing components in aerospace applications is confirmed by these results.</p> Graphical abstract <p></p>

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Development and investigation of mechanical characterization of 3D printed hybrid layer acrylonitrile butadiene styrene plus-polyethylene terephthalate glycol for the application of aircraft sector

  • 期刊论文

  • 发表日期：

    2026年5月11日

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  • Senthil Kumar Bella Raman,
  • Yokeswaran Ramadoss,
  • Rathinavel Subbiah,
  • Senthilkumar Thangarajan Sivasankaran

摘要

In this work, a novel hybrid filament structure that combines polyethylene terephthalate glycol (PETG) and acrylonitrile butadiene styrene plus (ABS PLUS) is developed to evaluate the mechanical performance for aeronautical support applications. This study’s main contribution is the examination of the impact, flexural, and tensile characteristics of multi-material specimens made with the fused filament fabrication (FFF) method. To maximize mechanical performance, different combinations of layer thickness, infill density, and printing speed were investigated. The highest ultimate tensile strength was demonstrated by Specimen 6, which was printed at 40 mm/s, 0.15 mm layer thickness, and 45% infill density. The highest flexural strength was demonstrated by specimen 4, which had a 0.15 mm layer thickness, a 15% infill density, and a 60 mm/s speed. The highest impact strength was noted in Specimens 6 and 7, which were printed at 60 mm/s and 80 mm/s, respectively, with 0.15 and 0.2 mm layer thicknesses and 15% infill densities. Interestingly, the hybrid structure’s maximum tensile strength (36.5 N/mm² in Specimen 9) was much higher than the usual values for ABS (20–30 N/mm²) and regular PETG (20–25 N/mm²), indicating the synergistic increase made possible by ABS PLUS–PETG hybrid stacking. The potential of this hybrid material system for lightweight, load-bearing components in aerospace applications is confirmed by these results.

Graphical abstract