On Development of Alternating Layer Acrylonitrile Butadiene Styrene-Al Composite Structures Using Additive Manufacturing

Fused filament fabrication (FFF) is one of the low-cost 3D printing techniques for the preparation of innovative composite structures using thermoplastic materials. The manufacturing of mechanically sustainable composites structures are currently needed. In the recent past, few scientific studies have reported modifying the mechanical properties of thermoplastic material using the metal spraying method by the FFF process. In this study, the acrylonitrile butadiene styrene (ABS-based thermoplastic composites structures have been prepared by Aluminum (Al) metal spray. To investigate the effect of Al spray reinforcement, three input parameters have been selected: the number of sprayed layers (2, 3, and 4), infill pattern (line, triangle, and cubic), and infill density (60, 80, and 100%). The results of the study suggested that maximum strength at peak and maximum strength at break have been observed for composite structures prepared with three number of Al spray layers, triangular-shaped infill printing pattern, and 100% infill density. The genetic algorithm-based multi-objective analysis has been performed for the selection of optimum process parameters. Results of the study were supported with crystallinity analysis using x-ray diffraction (XRD), particle analysis using a scanning electron microscope (SEM), and fracture analysis using optical microscopy.