Fabrication and characterization of high-performance heat-resistant acrylonitrile–butadiene–styrene (ABS) composites reinforced with carbon fibers

Abstract Acrylonitrile–butadiene–styrene (ABS) is extensively utilized in 3D printing applications, though its mechanical strength and thermal resistance remain limiting factors. This study developed five distinct ABS/carbon fiber (CF) composite filaments using CF as a modifier. The incorporation of CF significantly enhanced the matrix’s mechanical properties and thermal stability through its superior strength and heat resistance. A comprehensive investigation was conducted using fused deposition modeling (FDM) technology to optimize printing parameters, dimensional accuracy, and mechanical performance. Experimental results demonstrated that increasing platform temperature improved interlayer adhesion and reduced bubble formation, while excessive temperatures caused deformation. Elevated printing temperatures enhanced interlayer bonding strength, though extreme temperatures induced material degradation. The infill pattern directly influenced mechanical property distribution, and higher infill density improved tensile strength at the expense of extended printing duration and material consumption. For the composite containing 5 wt% CF, optimal parameters were established: build platform temperature of 110 °C, nozzle temperature of 240 °C, linear infill pattern, and 100 % infill density. Comparative analysis revealed increased printing deviation (0.02 mm–0.39 mm) relative to pure ABS, alongside significant enhancements in thermal and mechanical properties: 30.3 % increase in glass transition temperature, 18.9 % improvement in tensile strength, and 64.86 % augmentation in impact toughness.