Enhancing mechanical and surface properties of 3D-Printed Kevlar-reinforced ABS/PLA composites through FDM process

Hybrid Advances Pub Date : 2025-06-01 DOI:10.1016/j.hybadv.2025.100510

Narayan Chandra Ray , Rotan Kumar Saha , Md Easin Mollah , Shaikh Rakib , Yusuf Ali

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Abstract

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.

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通过FDM工艺提高3d打印凯夫拉增强ABS/PLA复合材料的机械性能和表面性能

本研究研究了通过熔融沉积建模（FDM）工艺制备的芳纶增强丙烯腈-丁二烯-苯乙烯（ABS）和聚乳酸（PLA）复合材料的力学和表面性能，目的是提高材料的性能，用于先进的工程应用。在聚合物基体中加入不同浓度的凯夫拉粉，并通过拉伸、弯曲、韧性、硬度和表面粗糙度测试来评估复合材料。结果表明：经Kevlar增强后，合金的抗拉强度和韧性分别提高了32.55%和9.24%，硬度提高了8.98%，具有较好的耐磨性；此外，表面粗糙度分析表明，纯PLA和ABS具有最光滑的表面光洁度；然而，S3 （95% ABS + 5%凯夫拉粉）样品在力学性能和表面质量之间取得了最有利的平衡，使其成为测试样品中的最佳配方。扫描电镜（SEM）证实了均匀的凯夫拉分散，导致更好的结构完整性和减少缺陷形成。表面形貌分析表明，S3复合材料的平均表面高度最低（0.5373 nm），平均颗粒面积最大（44.74 μm2），强化相分布均匀。而S4 （90% ABS+ 10% Kevlar粉末）样品的平均表面高度显著提高（230.1 nm），平均颗粒面积显著减小（11.07 μm2），表明表面不规则性和缺陷增加。这些发现凸显了凯夫拉增强ABS/PLA复合材料在汽车、航空航天和防护设备领域轻量化、高强度应用的潜力。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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Hybrid Advances

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