Driving sustainability and performance: 3D-printing of lightweight functional components using recycled carbon fiber reinforced polyphenylene sulfide composites for automotive industry

This paper focuses on the 3D printing of Polyphenylene Sulfide (PPS) reinforced with 5 and 10 wt% recycled carbon fiber (rCF), alongside its neat counterparts, using material extrusion additive manufacturing. Moreover, the addition of 10% rCF significantly improved crashworthiness by over 60% compared to engineered PPS plastic. Young’s modulus and impact strength were enhanced by 78 and 64%, respectively, compared to the neat sample. The temperature at which half of the sample’s weight degrades increased by 50 °C compared to the unreinforced PPS. Additionally, the printed parts displayed excellent chemical resistance, with fluid uptake of less than 1% and a mere 10% reduction in tensile strength after one week of immersion in automobile chemicals. These findings suggest that the developed PPS/10rCF has the potential to be a noteworthy candidate in ‘under-the-hood’ applications. This advanced manufacturing of functional materials, based on reclaimed carbon fiber, underscores the diverse capabilities of recycled materials in producing high-value products across various sectors, including transportation, appliances, electronics, energy storage devices, and building construction.