Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process
This study investigates the mechanical and surface properties of Kevlar-reinforced acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) composites fabricated via the fused deposition modeling (FDM) process, with the goal of enhancing material performance for advanced engineering applicati...
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| Language: | English |
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Elsevier
2025-12-01
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| Series: | Hybrid Advances |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2773207X25001344 |
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| author | Narayan Chandra Ray Rotan Kumar Saha Md Easin Mollah Shaikh Rakib Yusuf Ali |
| author_facet | Narayan Chandra Ray Rotan Kumar Saha Md Easin Mollah Shaikh Rakib Yusuf Ali |
| author_sort | Narayan Chandra Ray |
| collection | DOAJ |
| description | This study investigates the mechanical and surface properties of Kevlar-reinforced acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) composites fabricated via the fused deposition modeling (FDM) process, with the goal of enhancing material performance for advanced engineering applications. Various Kevlar powder concentrations were integrated into the polymer matrix, and the composites were evaluated through tensile, flexural, toughness, hardness, and surface roughness tests. The results demonstrated that Kevlar reinforcement significantly enhanced tensile strength and toughness by 32.55 % and 9.24 %, respectively, while hardness improved by 8.98 %, contributing to greater wear resistance. Additionally, surface roughness analysis revealed that pure PLA and ABS exhibited the smoothest surface finishes; however, the S3 (95 % ABS + 5 % Kevlar powder) sample, achieved the most favorable balance between mechanical performance and surface quality, making it the optimal formulation among the tested specimens. Scanning electron microscopy (SEM) confirmed uniform Kevlar dispersion, leading to better structural integrity and reduced defect formation. Surface topography analysis showed that the S3 composite exhibited the lowest mean surface height (0.5373 nm) and the largest mean particle area (44.74 μm2), suggesting a well-distributed reinforcement phase. However, S4 (90 % ABS+10 % Kevlar powder) sample displayed a significantly higher mean surface height (230.1 nm) and a reduced mean particle area (11.07 μm2), indicating increased surface irregularities and imperfections. These findings highlight the potential of Kevlar-reinforced ABS/PLA composites for lightweight, high-strength applications in the automotive, aerospace, and protective equipment sectors. |
| format | Article |
| id | doaj-art-7d2869cc341d432687660d6c7269baed |
| institution | OA Journals |
| issn | 2773-207X |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Hybrid Advances |
| spelling | doaj-art-7d2869cc341d432687660d6c7269baed2025-08-20T02:32:31ZengElsevierHybrid Advances2773-207X2025-12-011110051010.1016/j.hybadv.2025.100510Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM processNarayan Chandra Ray0Rotan Kumar Saha1Md Easin Mollah2Shaikh Rakib3Yusuf Ali4Department of Industrial and Production Engineering, Dhaka University of Engineering & Technology, Gazipur, BangladeshDepartment of Industrial and Production Engineering, Dhaka University of Engineering & Technology, Gazipur, Bangladesh; Corresponding author.Department of Industrial and Production Engineering, Dhaka University of Engineering & Technology, Gazipur, BangladeshDepartment of Industrial and Production Engineering, Dhaka University of Engineering & Technology, Gazipur, BangladeshDepartment of Mechanical Engineering, International University of Business Agriculture and Technology, Dhaka, BangladeshThis study investigates the mechanical and surface properties of Kevlar-reinforced acrylonitrile butadiene styrene (ABS) and polylactic acid (PLA) composites fabricated via the fused deposition modeling (FDM) process, with the goal of enhancing material performance for advanced engineering applications. Various Kevlar powder concentrations were integrated into the polymer matrix, and the composites were evaluated through tensile, flexural, toughness, hardness, and surface roughness tests. The results demonstrated that Kevlar reinforcement significantly enhanced tensile strength and toughness by 32.55 % and 9.24 %, respectively, while hardness improved by 8.98 %, contributing to greater wear resistance. Additionally, surface roughness analysis revealed that pure PLA and ABS exhibited the smoothest surface finishes; however, the S3 (95 % ABS + 5 % Kevlar powder) sample, achieved the most favorable balance between mechanical performance and surface quality, making it the optimal formulation among the tested specimens. Scanning electron microscopy (SEM) confirmed uniform Kevlar dispersion, leading to better structural integrity and reduced defect formation. Surface topography analysis showed that the S3 composite exhibited the lowest mean surface height (0.5373 nm) and the largest mean particle area (44.74 μm2), suggesting a well-distributed reinforcement phase. However, S4 (90 % ABS+10 % Kevlar powder) sample displayed a significantly higher mean surface height (230.1 nm) and a reduced mean particle area (11.07 μm2), indicating increased surface irregularities and imperfections. These findings highlight the potential of Kevlar-reinforced ABS/PLA composites for lightweight, high-strength applications in the automotive, aerospace, and protective equipment sectors.http://www.sciencedirect.com/science/article/pii/S2773207X250013443D printingMechanical and surface propertiesKevlar powderReinforced compositesFused deposition modeling |
| spellingShingle | Narayan Chandra Ray Rotan Kumar Saha Md Easin Mollah Shaikh Rakib Yusuf Ali Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process Hybrid Advances 3D printing Mechanical and surface properties Kevlar powder Reinforced composites Fused deposition modeling |
| title | Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process |
| title_full | Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process |
| title_fullStr | Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process |
| title_full_unstemmed | Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process |
| title_short | Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process |
| title_sort | enhancing mechanical and surface properties of 3d printed kevlar reinforced abs pla composites through fdm process |
| topic | 3D printing Mechanical and surface properties Kevlar powder Reinforced composites Fused deposition modeling |
| url | http://www.sciencedirect.com/science/article/pii/S2773207X25001344 |
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