Repercussion of Process Parameters on the Mechanical Peculiarity of Additive Manufactured Components

This work addresses the influence of layer thickness and geometric pattern, along with pattern density on the mechanical properties of carbon fiber (CF)-reinforced acrylonitrile butadiene styrene (ABS) specimens developed through the fused filament fabrication (FFF) technique. Specimens prepared using three printing parameters with three levels were tested for mechanical performance. The triangular pattern shows the highest flexural strength (72.0 MPa), but the honeycomb pattern had better tensile strength (42.1 MPa) and impact resistance (2.6 kJ/m2) based on the results. The higher the infill density and print layer thickness, the higher the mechanical properties, although only small improvements could be detected beyond 85% infill and 0.2 mm thickness. The brick pattern scored low in every mechanical test. A combination of 85% and 95% infill, and a layer thickness of 0.30 mm, together with the selection of application-specific patterns, yielded optimal mechanical performance. These results offer successful support for the FFF parameters’ optimization in both structural and load-bearing usages with the help of ABS+CF composites, and provide better performance with the help of personalized print parameters.