This study investigates the effect of key manufacturing parameters and graphene nanoparticle additions on the tensile behavior of fiber metal laminates (FMLs) using a Taguchi-based experimental design. Several manufacturing parameters were considered: laminate configuration (glass fiber and hybrid glass-carbon fiber reinforcement), aluminum surface treatment (chemical treatment and laser surface texturing with scanning spacings of 1 mm and 2 mm), aluminum thickness (0.5, 0.7, and 1.0 mm), graphene nanoparticle content (0, 0.1, and 0.25 wt%), and curing pressure (2, 5, and 7 bar). Eighteen FMLs specimens were fabricated according to the Taguchi orthogonal array and tested under tensile loading. Ultimate tensile strength ( \(\:{\upsigma\:}\) ult), tensile modulus (E), toughness modulus (UT), and failure strain ( \(\:\epsilon\:\) f) were evaluated as performance responses. The findings show laminate configuration significantly affects \(\:{\upsigma\:}\) ult, UT, and \(\:\epsilon\:\) f, with the all-glass fiber configuration exhibiting superior performance responses. Graphene content and curing pressure had a minimal effect on tensile properties. The optimal parameter combination for \(\:{\upsigma\:}\) ult and UT involved a glass fiber laminate configuration with chemically treated aluminum, an aluminum thickness of 0.5 mm, 0% graphene, and a curing pressure of 2 bar. Optimal parameters for E include a laser 1 mm scanning texture, glass fiber laminate configuration, aluminum thickness of 0.5 mm, 0% graphene nanoparticles, and a curing pressure of 5 bar. Additionally, optimal parameters for \(\:\epsilon\:\) f are glass fiber configuration, chemical surface treatment, aluminum thickness of 1 mm, 0% graphene, and curing pressure of 2 bar. Validation tests indicated the model’s predictions were accurate, with prediction errors under 5%, highlighting its statistical reliability.
