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As a typical 3D printing process, fused filament fabrication still has disadvantages when operating on manufacturing lines due to the non-uniform textures of the oriented surfaces of the 3D-printed components. This work investigates the effects of structural parameters, i.e., orientations angle, ABS and PLA materials, three different layer thicknesses, three different perimeters, and three different infill rates utilizing a balanced modified Taguchi experimental design and 63 different parametric combinations to characterize the surface roughness parameters: average Ra, mean roughness depth Rz, root mean square Rq, skewness Rsk, and kurtosis Rku. The analysis of the experimental results, i.e., the levels mean values analysis plots and linear residual analysis of variances, showed that the layer thickness strongly influences all surface parameters and interacts considerably with all orientations. In contrast, material type, number of perimeters, and infill rate had insignificant impacts on surface roughness parameters. Finally, the additive linear modelling approach was utilized and validated for proper predictions, making it helpful for surface engineering applications. [ABSTRACT FROM AUTHOR]

Formulating polymer blends is of vital scientific and industrial interest because of their low cost and the possibility of producing new materials with tailored properties. In this research, polypropylene (PP)/acrylonitrile–butadiene–styrene (ABS) polymer blends were prepared using styrene-ethylene-butylene-styrene (SEBS) and styrene-ethylene-propylene (SEP) copolymers. The polymer blends were extruded and injection molded to evaluate the mechanical, rheological, thermal, and thermomechanical properties, infrared spectroscopy, and morphology. Incorporating SEBS and SEP copolymers into the PP/ABS blend increased the torque and reduced the melt flow index, indicating higher viscosity than the PP/ABS base system. As a result, improved compatibility of PP/ABS/SEBS and PP/ABS/SEP blends was achieved, thereby improving the mechanical properties of PP/ABS. However, the SEBS copolymer was more effective. Compared to neat PP, the PP/ABS/SEBS blend with 15% SEBS showed increases in impact strength, elongation at break, and heat deflection temperature (HDT) of 87%, 107%, and 7%, respectively. In addition, the elastic modulus and Shore D hardness were in line with neat PP, and thermal stability measured through thermogravimetry exceeded that of PP by 8 °C. Evidence of fractured ABS particles in the PP matrix was seen in the scanning electron microscopy (SEM) morphology, suggesting that SEBS migrated to the interface. SEBS also remained dispersed in the PP matrix, as confirmed by selective phase extraction, which favored a synergic effect of properties in the PP/ABS/SEBS blend (70/15/15%). This blend offered potential for applications such as toys, furniture accessories, packaging, and housewares. [ABSTRACT FROM AUTHOR]

The paper describes the type of changes in the structure and mechanical properties of 3D printed shapes under the influence of mineral oil. The effects of a room (23 °C) and elevated temperature (70 °C) on 3D prints manufactured by the FDM method and stored in oil for 15, 30, and 60 days on the change of properties and structure were investigated. The samples were produced from ABS (poly(acrylonitrile-co-butadiene-co-styrene)), ASA (poly(acrylonitrile-co-styrene-co-acrylate), PLA (poly(lactic acid)), and HIPS (high-impact polystyrene). Tests related to the strength of the materials, such as the static tensile test and Charpy impact test, were carried out. The structure was evaluated using a scanning electron microscope, and changes in chemical structure were determined by conducting FTIR (Fourier transform infrared spectroscopy) and TGA (thermogravimetric analysis) tests. The analysis of the results provided important information about the impact of mineral oil on specific materials. This is critical for designing and manufacturing components that can withstand mineral oil exposure in real-world environments. The materials underwent varying changes. Strength increased for PLA by about 28%, remained unchanged for ABS and HIPS during exposure for 30 days, and decreased for ASA with extended exposure up to 14%. [ABSTRACT FROM AUTHOR]

Ultrasonic welding (USW) of thermoplastics plays a significant role in the automobile industry. In this study, the effect of the welding time on the joint strength of ultrasonically welded acrylonitrile–butadiene–styrene (ABS) and the weld formation mechanism were investigated. The results showed that the peak load firstly increased to a maximum value of 3.4 kN and then dropped with further extension of the welding time, whereas the weld area increased continuously until reaching a plateau. The optimal welding variables for the USW of ABS were a welding time of 1.3 s with a welding pressure of 0.13 MPa. Interfacial failure and workpiece breakage were the main failure modes of the joints. The application of real-time horn displacement into a finite element model could improve the simulation accuracy of weld formation. The simulated results were close to the experimental results, and the welding process of the USW of ABS made with a 1.7 s welding time can be divided into five phases based on the amplitude and horn displacement change: weld initiation (Phase I), horn retraction (Phase II), melt-and-flow equilibrium (Phase III), horn indentation and squeeze out (Phase IV) and weld solidification (Phase V). Obvious pores emerged during Phase IV, owing to the thermal decomposition of the ABS. This study yielded a fundamental understanding of the USW of ABS and provides a theoretical basis and technological support for further application and promotion of other ultrasonically welded thermoplastic composites. [ABSTRACT FROM AUTHOR]

Thermoplastic polyurethane (TPU) has emerged as extremely benign materials for next-generation manufacturing using additive manufacturing processes due to its favorable mechanical properties, durability, and as well as biocompatibility. However, the lack of stiffness of TPU affects its buckling strength and performance efficiency. Therefore, an efficient method of optimization of a 3D-printable composition of TPU-based blends is necessary. In this work, attempts were made to explore material extrusion additive manufacturing technique of acrylonitrile–butadiene–styrene (ABS)/TPU blends with particular reference to mechanical and damping behaviour. Design of experiment (DoE) was used to determine the optimum printing parameters. Rheological studies were exploited to understand the printability, and optimum 3D-printable blend composition. The damping behaviour of each blend composition was calculated and a damping ratio (ξ) between 1 ≤ ξ ≤ 2 was observed for 40 wt% ABS loading, which raised to 1 ≤ ξ ≤ 4 for 80 wt% ABS loaded blend specimen. Furthermore, for ABS incorporated TPU, a significant enhancement of stiffness over neat TPU was achieved, thereby reasonably addressing the filament stiffness issue. This work introduces an efficient method of improving TPU filament printability while parallelly identifying the printable blend composition which can be beneficial for several potential applications. [ABSTRACT FROM AUTHOR]

Printability and interlayer adhesion are the most critical issues in 3D printing of immiscible polymer blends. It can affect structural integrity and mechanical performance of the printed parts. In this work, an effective strategy to improve the printability and interlayer adhesion of immiscible acrylonitrile‐butadiene‐styrene/polypropylene (ABS/PP) blends was implemented by introducing styrene–ethylene/butylene–styrene copolymer grafted with maleic anhydride (SEBS‐g‐MA) as a compatibilizer. The printability of the developed blends was investigated using rheological properties such as absolute value of complex viscosity, loss tangent and die‐swell ratio. Interestingly, it was found that the additive manufactured blends with 20 wt% SEBS‐g‐MA loading showed improved interlaminar shear strength, impact strength, Young's modulus and toughness as compared with the pure blend. Fractography analysis revealed that two different possible failure mechanisms, interface and matrix failure were apparent in the 3D printed samples with and without SEBS‐g‐MA content. This work provides a promising pathway to fabricate the complex structures from polymer blends with improved mechanical properties and surface finish. Highlights: This study demonstrated improved interlayer adhesion at the printed interface of immiscible ABS/PP blends in presence of SEBS‐g‐MA.The printability of the developed blends was predicted from rheological properties.Additive manufactured blends with SEBS‐g‐MA loading showed improved mechanical performance. [ABSTRACT FROM AUTHOR]

This study is focused on the application of 3D-printed elements and conventional elements to create a prototype of a custom-made exoskeleton for lower limb rehabilitation. The 3D-printed elements were produced by using Fused Deposition Modeling technology and acrylonitrile butadiene styrene (ABS) material. The scope of this work involved the design and construction of an exoskeleton, experimental testing of the ABS material and numerical research by using the finite element method. On the basis of the obtained results, it was possible to deduce whether the load-bearing 3D-printed elements can be used in the proposed mechanical construction. The work contains full data of the material models used in FEM modeling, taking into account the orthotropic properties of the ABS material. Various types of finite elements were used in the presented FE models. The work is a comprehensive combination of material testing issues with the possibility of implementing the obtained results in numerical strength models of machine parts. [ABSTRACT FROM AUTHOR]

Bonsai is a kind of classical art in China and Japan. The traditional method of bonsai shaping of miniature trees is technical and usually requires experienced horticulturists to successfully carry out the process. In order to let ordinary people feel the fun of bonsai shaping, this paper proposes a fast bonsai shaping method, i.e., by use of a plastic guiding mold with customized shape, which is processed by fused deposition 3D printing technology. The tree seedling is bundled onto the mold, and the shape of the mold guides the growth of the tree seedling, thus achieving the purpose of bonsai shaping. In order to further improve the bending properties of the bonsai guiding mold, this paper investigated the main 3D printing parameters of ABS filament. The results showed that with the decrease of printing speed, the increase of extrusion temperature, and the increase of hot bed temperature, the bending strength and elastic modulus of ABS specimens increased, and the bending properties was enhanced; the optimal printing speed was 50 mm/s, the extrusion temperature was 230 °C, and the hot bed temperature was 80 °C. The mechanical properties of the bonsai guiding mold manufactured based on the optimal process parameters were better, the print quality was higher, and it had high practical value. [ABSTRACT FROM AUTHOR]

Acrylonitrile butadiene styrene (ABS) is a commonly used copolymer. It is widely employed, especially in additive manufacturing (AM), a newly developed and open-ended production method. It can be used in medical applications due to its biocompatible behaviour and performance characteristics. Though there are a few disadvantages of the AM, improving the sample's mechanical properties are possible by applying pre-processing to the filament (dehumidification) or choosing the correct printing parameters. Nevertheless, surface quality is limited regardless of the mechanical properties and printing parameters. For this reason, finishing, called post-processing, is often preferred. ABS post-process application is made with an acetone vapour atmosphere. However, this application is a chemical process. This chemical process could change the properties of the ABS sample. This paper investigates the effect of post-processing on the ABS sample. According to reference samples, the change in porosity values was measured from 30 to 60%. In addition, as the post-processing time increased, the hue of the samples shifted from yellow to blue and from dark to light. Further, increased acetone vapour exposure decreased the bending and tensile test results. The impact of acetone vapour exposure on the toughness of ABS polymer has yielded conflicting results. [ABSTRACT FROM AUTHOR]

The use of polymers is desirable in the industries where weight reduction and corrosion resistance are required, such as in the automotive industry where weight reduction directly relates to fuel conservation. Acrylonitrile butadiene styrene (ABS) is a type of polymer used in aerospace, railway, automotive, and consumer goods industries. This research article investigates the use of friction stir welding (FSW) to join ABS polymer. Compared to traditional metal-based products, polymers offer better formability, design flexibility, and ease of processing. The process parameters were optimized based on tensile strength using Taguchi's L18 orthogonal array (OA). A maximum tensile strength of 19.4 MPa was obtained at a tool rotational speed of 224 rpm, a tool travel speed of 40 mm/min, external heat of 45 °C, and a tool shoulder diameter of 16 mm. Transmission electron microscopy was used to analyze the microstructural characteristics, while Vickers microhardness tester and tensometer were used to examine the mechanical properties. The strength of the joint was affected due to the butadiene rubber particles breaking or weakening in the stir zone). Moreover, to identify the location of failure, three additional tensile coupons were taken from Experiment No. 13, and a 1-mm-deep notch was machined in all of them at the Center, AS, and RS. The findings revealed that the tensile coupon with the notch at RS had a tensile strength of 19.4 MPa, which is 60% relative to the base material. The retreating side of Experiment No. 13 exhibited a Vickers microhardness of 14.3 HV, which was higher than the base material's Vickers microhardness of 13.8 HV, indicating that it became harder. [ABSTRACT FROM AUTHOR]

The implementation of three-dimensional (3D) printing technology has culminated in a notable rise in productivity and operational effectiveness for manufacturers. Additive manufacturing (AM) is a manufacturing technology that implies an alteration from the conventional approach of material removal. The fundamental idea underlying the AM technique is the gradual buildup of layers (layer-on-layer accumulation). In conventional approaches, every component can have detrimental implications due to the direct interaction between the tool and the workpiece, leading to the loss of heat through friction. The utilisation of 3D printing as a way to surpass conventional processing methods signifies a novel development in several sectors. This method involves the utilisation of unconventional techniques for the fabrication of components. The primary objective of this research is to investigate the chemical vapour jet drilling technique specifically applied to acrylonitrile butadiene styrene (ABS) materials. The intent is to enhance the surface characteristics, or surface finish (SF), and the dimensional accuracy (DA) of ABS workpieces. An evaluation regarding the reliability, repeatability, as well as preciseness of the vapour jet drilling (VJD) process is conducted via the utilisation of experiment and data analysis. The study employed a Taguchi L9 design of experiments to carry out a series of tests aimed at analysing the implications of three independent variables: pressure, flow rate, and standoff distance. The researchers employed a multiresponse optimisation approach to attain an optimal combination of parameters that resulted in a superior SF with DA. Consequently, the overall appeal of the outcome was reached. The process’s capabilities and dependability were assessed by conducting tests on the substrates at their optimal settings. Surface roughness and circularity were measured at numerous locations on the substrates. The study determined that the process capability indices (C p and C pk) had values over 1.33 for each of the response parameters, with C pk values also exceeding 1. The analysis of histograms and capability indices demonstrates that the VJD method, when conducted under optimised conditions, may be categorised as statistically controlled for the processing of ABS materials.

The rapid and solid joining of thermoplastic to metal is of great significance for structural lightweighting. A thermoplastic acrylonitrile butadiene styrene (ABS) and laser textured 5052 Al is joined by ultrasonic welding with longitude wave in this study. Influence of the texturing type on microstructure and joint strength are investigated. Experimental results showed that the texturing type was a major factor in joint strength, and the mesh array was superior than circular hole array in terms of joint strength. The maximum joint strength of 17.87 MPa was obtained in L1, which was about 2.4 times and 3.6 times of these other two cases. Interfacial and cohesive failure mode was observed, and the fracture surface can be divided into four different parts: light black mark Region Ⅰ, transitional Region Ⅱ, Region Ⅲ with dense residues, and porous structure Region Ⅳ. The joint strength increased with the increase of Regions Ⅱ and Ⅲ while dropped with the occurrence of Region Ⅳ. Thermal decomposition of ABS composite resulted from the high temperature during welding process was responsible for the formation of Region Ⅳ. The joining mechanism in UW of ABS to laser textured 5052 Al was mechanical interlocking. Successful joining of ABS/Al hybrid structure by ultrasonic welding appears to be a reliable and potential technique for industrial applications.

Unconventional injection methods include i.e. blowing injection that allows for production of moldings with a lower weight while maintaining mechanical properties of detail. Due to the fact that most polymers are dyed at the processing stage, it is important to examine the simultaneous effect of blowing and colorbatch, as well as variable processing conditions, on the functional properties of moldings made of the most popular construction material, i.e. ABS. Samples were made of ABS polymer without and with the addition of a colorbatch containing brown pigment on ABS matrix, and blowing agent. Variable processing conditions were: mold and injection temperature, holding pressure and time. Other parameters were constant. Samples were tested for basic functional properties such as color, gloss, mass, density and thickness. Moldings produced with a higher blowing agent content and a higher injection temperature were characterized by lower mass. No significant influence of processing parameters and content of colorbatch on mass of samples was found. Blowing agent has no significant impact on thickness of moldings, regardless of processing conditions. Addition of a colorbatch influenced samples’ gloss. Increase in colorbatch and blowing agent content and mold temperature allow to obtain moldings with a higher surface gloss. Colorbatch also changed color of samples – a decrease in luminance L even by about 40% and great changes in parameters “a” and slight changes in parameter “b”. It was found that blowing agent content had the greatest influence on density of moldings. Injection temperature and colorbatch, do not significantly affect density of moldings.

In this work, the incorporation of halloysite nanotubes (HNTs) and polyphenylene ether-grafted maleic anhydride copolymer (FB) into acrylonitrile butadiene styrene (ABS)/polyphenylene oxide (PPO) blend has been investigated to enhance the compatibility and performance of the blends. ABS/PPO blend (AP) with the weight ratio of ABS/PPO = 70/30 with 5 wt% loading of FB and different weight contents of HNTs were elaborated by melt blending process, and their properties were studied. The SEM observation revealed that AP blend exhibited dispersed phases of PPO droplets with apparent gaps between PPO and ABS phases, indicating poor adhesion between the polymers in the blend. As the compatibilizer, FB effectively enhanced the inter-phase interaction, minimizing the formation of interfacial gaps, evidenced by the SEM images, leading to the adhesion between ABS, PPO, and HNTs phases. As a result, the mechanical performance of the AP blend was significantly improved with the addition of FB and HNTs. At 5 wt% of HNT, the AP/FB/HNT blend exhibited the tensile strength of 37.47 MPa and flexural strength of 59.09 MPa compared to 26.60 MPa and 39.45 MPa of neat AP, respectively. The glass transition temperature of the modified blends showed shifts compared to the neat AP, which indicates the improvement in miscibility of the modified-AP blends. The thermal stability and flame resistance of the blends were also enhanced with the introduction of HNTs and FB, evidenced by the V-1 rating in the UL-94 test and the increase in limiting oxygen index (LOI). These results demonstrated that the incorporation of HNTs and FB is a promising and straightforward method to improve the properties of ABS/PPO blends. [ABSTRACT FROM AUTHOR]

Biocomposites made from natural fibers have attracted significant attention in recent years owing to the global concern regarding plastic accumulation. In this investigation, ramie fiber was employed as a natural fiber reinforcement in the acrylonitrile butadiene styrene (ABS) matrix to enhance the biodegradability of the polymer composite. ABS/ramie fiber composites were prepared by compression molding with various wt% (5, 10, 15, and 20 wt %) of ramie fibers within the ABS matrix. Subsequently, the biodegradability, water absorption, mechanical properties, viscoelastic behavior, and thermal characteristics of the prepared composites were evaluated. The biodegradation test results demonstrated that there was a positive correlation between the concentrations of fibers in neat ABS. The maximum biodegradation of the composites was 2.56% at 20 wt% ramie fibers in the ABS matrix. Moreover, an increase in the wt% of ramie fiber led to an increase in water absorption. Although the tensile strength and impact strength decreased with increasing fiber content, the tensile modulus of the ABS/ramie fiber composites initially increased up to 5 wt% fiber and then started decreasing, and the natural fibers in ABS reduced the viscoelastic properties. The objective of developing ABS/ramie fiber composites is to utilize them as environmentally sustainable materials in automotive manufacturing industry. [ABSTRACT FROM AUTHOR]

This study investigated the influence of two key printing parameters--namely, layer thickness and infill percentage and also the annealing effect, on the hardness of PLA and ABS components. Employing the design of experiment (DOE) methodology, the most significant factor influencing the Shore D hardness values for each material was established, in addition to determining the optimal printing parameters that yield maximum hardness in the printed parts. Our findings reveal that layer thickness significantly impacts the hardness of 3D printed PLA and ABS specimens, with printing infill percentage exerting a comparatively smaller influence, while in case of PLA annealed samples, the most significant factor is infill percentage. [ABSTRACT FROM AUTHOR]

In this work, a self-lubricating composite was manufactured using a novel hybrid 3D printing/in situ spraying process that involved the printing of an acrylonitrile butadiene styrene (ABS) matrix using fused deposition modeling (FDM), along with the in situ spraying of alumina (Al2O3) and hexagonal boron nitride (hBN) reinforcements during 3D printing. The results revealed that the addition of the reinforcement induced an extensive formation of micropores throughout the ABS structure. Under tensile-loading conditions, the mechanical strength and cohesive interlayer bonding of the composites were diminished due to the presence of these micropores. However, under tribological conditions, the presence of the Al2O3 and hBN reinforcement improved the frictional resistance of ABS in extreme loading conditions. This improvement in frictional resistance was attributed to the ability of the Al2O3 reinforcement to support the external tribo-load and the shearing-like ability of hBN reinforcement during sliding. Collectively, this work provides novel insights into the possibility of designing tribologically robust ABS components through the addition of in situ-sprayed ceramic and solid-lubricant reinforcements. [ABSTRACT FROM AUTHOR]

This paper investigates the effects of sodium laureth sulfate (SLES) on the wettability of the surface of the two most common recycled plastics in refrigeration equipment: HIPS (high-impact polystyrene) and ABS (acrylonitrile–butadiene–styrene). These plastics, in the form of flakes, were identified on the basis of their FTIR spectra, and then, they were subjected to a study of contact angles using the sessile droplet method. The solutions for the angle analysis included tap water with the addition of SLES. The results of this study showed that at SLES concentrations of 0.1 g/L and 0.2 g/L, the differences in the contact angles for HIPS and ABS were 10.76° and 10.10°, respectively. This research confirmed the potential of using SLES as a support for the flotation separation of plastics with similar densities and surface characteristics, such as HIPS and ABS. [ABSTRACT FROM AUTHOR]

The effect of parameters of acrylonitrile butadiene styrene composites reinforced with carbon fabricated by fused deposition modeling was studied in this work. Parameters like infill density, raster angle, layer thickness, and printing parameters are varied and their influence on mechanical properties was analyzed experimentally. Experiments were planned by the design of experiments technique and mathematical equations were generated to analyze the impact of these parameters. ANOVA is involved to ensure the validity of the mathematical equations. The mechanism of the fractured samples was studied using scanning electron microscopy. The tensile strength of ABS/carbon fiber composites ranges from 21.74 to 28.09 N/mm2, while the flexural strength ranges from 2.62 to 3.14 N/mm2 and the impact strength ranges from 3.66 to 5.19 kJ/m2. The fracture of composites is characterized by cavities, infill gaps, bonding, dimples, tearing debonding of fiber, crack, delamination, shearing, crack, and fiber protrusion. The nature of failure varied from ductile to brittle depending upon the change in process parameters. [ABSTRACT FROM AUTHOR]

The increasing use of polymer products in transportation and almost all sectors is a distinctive sign of the current decade. On-site repair of defects along the spatial path are important advantages of a portable welding and repair system. The current article presented an in-house developed pneumatically powered portable set-up and tool for defect repair based on friction stir welding (FSW). The suggested tool can be used for welding polymer products such as car bumpers, motorboats, and polymer vessels. Further, acrylonitrile butadiene styrene (ABS) polymer specimens were joined by FSW and friction stir spot welding (FSSW), and the maximum temperature was monitored. FSW process parameters: rotational speed and traversing velocity, and FSSW parameter: rotational speed and dwell time, were varied, and the design of experiment-based investigations was carried out. Response surface method (RSM) and analysis of variance (ANOVA) were used to analyse the results. The acceptable results were obtained for rotational speed of less than or equal to 1100 rpm and welding velocity lower than 6.5 mm/min (for FSW). Good quality welds were obtained for dwell time equal to or higher than 25 s (for FSSW). The preferred temperature for a good quality weld was found to be 105°C in both processes. [ABSTRACT FROM AUTHOR]

This paper presents the results of research on the influence of the moisture content in a filament made of ABS polymer on the properties of products manufactured using FDM (fused deposition modeling). Tests were carried out on a standard printer, using the parameters recommended by the manufacturer and the literature on the subject. A special climatic chamber was used to condition the material. A negative impact of ABS filament moisture on the strength and dimensional accuracy of printed products and on the structure of their surface is demonstrated. When the range of the filament moisture is between 0.17% and 0.75%, the strength decreases by 25% and the sample thickness increases by 10%. It is also shown that this effect does not depend on the history of the polymer reaching a given moisture level, i.e., by absorbing moisture in the absorption process or releasing moisture in the desorption process. [ABSTRACT FROM AUTHOR]

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The characterization of compatibility is the key research content of polymer blending modification. The commonly used rheological characterization methods are mainly based on dynamic frequency scanning tests, while the tests in the low frequency region usually take long experimental time. Isotactic polypropylene (iPP)/acrylonitrilebutadiene- styrene graft copolymer (ABS) blends were investigated. The shear creep recovery mode of rotary rheometer was utilized to evaluate the compatibility of polymer blends. The obtained conclusions were further verified by using scanning electron microscopy. The results show that for incompatible iPP/ABS blends with different phase morphology, creep recoverable compliance ( Jr) exhibits different phenomena. The blends with co-continuous morphology show the highest creep recoverable compliance, while the Jr values of the blends with sea-island morphology are between those of the blends with co-continuous morphology and the pure components. When maleic anhydride grafted polypropylene (PP-g-MAH) and styrene-ethylene-butylene-styrene block copolymer (SEBS) were selected as compatibilizers, respectively, the Jr values of the compatibilized iPP/ABS blends are significantly lower than those of the pure components. This test is relatively short in time and could replace the common characterization methods to quickly evaluate the compatibility of polymer blends. [ABSTRACT FROM AUTHOR]

This paper presents the results of experimental investigation of the mechanical characteristics of 3D-printed acrylonitrile butadiene styrene (ABS) and its modifications reinforced with different types of short-fiber fillers: carbon, glass, and basalt. Elastic modulus, tensile and bending strength, as well as fracture toughness were determined in series of mechanical tests for samples produced with different manufacturing parameters, such as nozzle diameter and infill angle. It was found that the use of ABS filament reinforced with the short fibers can significantly improve the mechanical properties of 3D-printed devices when the infill angle is oriented along the vector of the applied load. In such a case, the elastic modulus and tensile strength can be increased by more than 1.7 and 1.5 times, respectively. The use of a larger nozzle diameter led to the growth of tensile strength by an average of 12.5%. When the macroscopic load is applied along the normal to the printed layers, the addition of short fibers does not give much gain in mechanical properties compared to pure ABS, which was confirmed by both standard tensile and fracture toughness tests. The surface of the fractured samples was examined using scanning electronic microscopy, which allowed us to make conclusions on the type of defects as well as on the level of adhesion between the polymeric matrix and different types of short fibers. [ABSTRACT FROM AUTHOR]

Temperature is very important in the fabrication of products developed for different applications, considering the widespread use of additive manufacturing (AM) technology. Thermal properties seriously affect the mechanical properties of products. In this study, the effect of printing nozzle temperature changes on the dimensional and mechanical properties of samples fabricated with acrylonitrile butadiene styrene (ABS) material was investigated. This material can be preferred over foam material for drone and model aircraft areas due to its low density. A total of thirty-six tensile test samples (ISO527–type1A) were fabricated with fused filament fabrication (FFF), one of the AM methods, and their dimensional properties (length, width, thickness, and mass) were determined. During the fabrication process, the nozzle temperature of the 3D (three-dimensional) printer was increased from 220 °C to 270 °C in 10 °C increments. All samples were subjected to tensile testing, and stress–strain values were measured. Analysis of variance (ANOVA) was applied to examine the effect of nozzle temperature change on the findings obtained as a result of the experimental study. The printing nozzle temperature significantly affected both the mechanical strength and dimensional properties of the samples. The samples showed lower viscosity and less hardness at higher nozzle temperatures. The mass and density of the samples decreased with increasing temperature. The tensile strength value decreased by 41.52%. [ABSTRACT FROM AUTHOR]

The advancement of polymers continues to expand relentlessly, becoming increasingly crucial to our daily existence. From high-performance sectors to mass-market industries, polymers permeate every facet of our lives. Consequently, it is imperative that we fully comprehend their properties, characteristics, and behavior. In this context, tensile testing are conducted, out on smooth and notched specimens machined from ABS plates to highlight the presence of residual stresses in the material. This study's objective is to describe how single and double-notched acrylonitrile butadiene styrene polymer specimens behave mechanically when in use. Additionally, to forecast the development of their harm and their immediate dependability. To do this static tensile tests on samples that have been, intentionally damaged by changing the defect length are used to compare the service lives of the damaged specimens. Additionally, the stages of damage were defined using a damage model known as the "unified theory," from which we can determine the critical life fraction βc and determine whether a single or double notch defect is more harmful. In order to identify the element with the lowest service life, we additionally calculated the specimens' dependability. Based on this research, we discovered that the life fraction for specimens with a single notch is lower than that for specimens with a double notch (for single notched and for double notched). As a result, single notched specimens have a shorter lifespan than double-notched specimens. To the conclusion, we also came that a single notch is less reliable than a double notch. [ABSTRACT FROM AUTHOR]

The present work proposes to investigate the effect of an ultrahigh molecular weight silicone rubber (UHMW-SR) and two ethylene methyl acrylate copolymers (EMA) with different methyl acrylate (MA) content on the mechanical and fire performance of a fireproof acrylonitrile butadiene styrene copolymer (ABS) composite, with an optimum amount of ammonium polyphosphate (APP) and aluminum diethyl phosphinate (AlPi). ABS formulations with a global flame retardant weight content of 20 wt.% (ABS P) were melt-compounded, with and without EMA and UHMW-SR, in a Brabender mixer. During this batch process, ABS P formulations with UHMW-SR and/or EMA registered lower torque values than those of ABS P. By means of scanning electron microscopy (SEM), it was possible to observe that all ABS composites exhibited a homogenous structure without phase separation or particle agglomeration. Slightly improved interfacial interaction between the well-dispersed flame-retardant particles in the presence of EMA and/or UHMW-SR was also noticed. Furthermore, synergies in mechanical properties by adding both EMA and UHMW-SR into ABS P were ascertained. An enhancement of molecular mobility that contributed to the softening of ABS P was observed under dynamic mechanical thermal analysis (DMTA). An improvement of its flexibility, ductility and toughness were also registered under three-point-bending trials, and even more remarkable synergies were noticed in Charpy notched impact strength. Particularly, a 212% increase was achieved when 5 wt.% of EMA with 29 wt.% of MA and 2 wt.% of UHMW-SR in ABS P (ABS E29 S P) were added. Thermogravimetric analysis (TGA) showed that the presence of EMA copolymers in ABS P formulations did not interfere with its thermal decomposition, whereas UHMW-SR presence decreased its thermal stability at the beginning of the decomposition. Although the addition of EMA or UHMW-SR, as well as the combination of both in ABS P increased the pHRR in cone calorimetry, UL 94 V-0 classification was maintained for all flame-retarded ABS composites. In addition, through SEM analysis of cone calorimetry sample residue, a more cohesive surface char layer, with Si-O-C network formation confirmed by Fourier transform infrared (FTIR), was shown in ABS P formulations with UHMW-SR. [ABSTRACT FROM AUTHOR]

Dispersion of carbon nanotubes in a thermoplastic polymer matrix is a big challenge in the research community. In the present study, multiwalled carbon nanotubes (MWCNTs) were dispersed in acrylonitrile butadiene styrene (ABS) polymer by a twin screw extruder to improve mechanical and thermal properties. The desired ratio of MWCNT in ABS (1, 2, and 3 wt.%) were dispersed through single and double extrusion processes by a twin screw extruder. The test specimens of produced composites and pure ABS materials were prepared by micro-injection molding. The nanocomposites' mechanical and thermal properties were investigated and compared with pure ABS. It has been found that the tensile strength has increased significantly for single-extruded and double-extruded composites. A comparative study of MWCNTs reinforced ABS nanocomposites and pure ABS was carried out using thermogravimetric analysis, Fourier's transform infrared, X-ray diffraction, and Scanning electron microscopy. It was found that the microhardness has also increased for single- and double-extruded nanocomposites in comparison to pure ABS. [ABSTRACT FROM AUTHOR]

Fused deposition modeling (FDM) is a commonly used 3D printing technique that involves heating, extruding, and depositing thermoplastic polymer filaments. The quality of FDM components is greatly influenced by the chosen processing settings. In this study, the Taguchi technique and artificial neural network were employed to predict the ultimate tensile strength of FDM components and establish a mathematical model. The mechanical properties of ABS were analyzed by varying parameters such as layer thickness, printing speed, direction angle, number of parameters, and nozzle temperature at five different levels. FDM 3D printers were used to fabricate samples for testing, following the ASTM-D638 standards, using the Taguchi orthogonal array experimental design method to set the process parameters. The results indicated that the printing process factors had a significant impact on tensile strength, with test values ranging from 31 to 38 MPa. The neural network achieved a maximum error of 5.518% when predicting tensile strength values, while the analytical model exhibited an error of 19.376%.

This study presents an investigation of the effects of structural characteristics, such as the layer height, infill density, top/bottom layer line directions and infill pattern, on the structural efficiency of Acrylonitrile Butadiene Styrene (ABS)-based specimens. The Fused Filament Fabrication (FFF) technique was utilized for the specimen fabrication, and the Ultimate Tensile Strength (UTS) and Strength-to-Mass (S/M) ratio were examined. The tests were planned according to the Central Composite Design (CCD), and an empirical model for each response was developed, with respect to the applied factors and their interactions. The analysis revealed that the characteristics with the strongest influence on the UTS and the S/M ratio were the infill and the layer height, respectively. Moreover, it was observed that the honeycomb structure contributed to the highest UTS compared to the other patterns. Finally, an optimization analysis based on the desirability function was performed, highlighting the combination of a 0.3 mm layer, 21.81% and 76.36% infill, 0° direction and the honeycomb pattern as the optimal for maximizing both UTS and S/M ratio under different desirability. [ABSTRACT FROM AUTHOR]

Mass customization is designing and manufacturing customized products with mass production efficiency and speed. Additive manufacturing (AM), one of the mass customization methods, is still expensive compared to mass production but continues to develop and become widespread daily. In addition, additive manufacturing has numerous limitations, such as slow print speed, less accuracy and repeatability, and limited material selection for a particular application. Therefore, this article determined the optimum parameters to improve dimensional accuracy in the AM method. The most common materials used in the additive manufacturing method are acrylonitrile butadiene styrene (ABS) and polylactic acid. Dimensional accuracy is one of the most critical parameters to meet quality standards in additive manufacturing, as in all production methods. Dimensional accuracy is the most critical parameter for smooth joining, especially for interlocking parts. The production parameters of an AM affect dimensional accuracy and the product's mechanical properties and surface quality. Optimal parameters vary to ensure dimensional accuracy in different ways. This study determined optimum parameters for dimensional accuracy, minimum filament consumption, and the production time of some basic shapes produced using ABS material by the FDM method. Cubic infill pattern, two shells, 50% infill pattern, and 0.2 mm wall thickness can be considered optimal for all shapes, although the optimal parameters for different shapes are different. Artificial neural networks (ANN) were used for the estimation of the experimental results. The estimations (R2) made by ANN in this study are over 90%. [ABSTRACT FROM AUTHOR]

Acrylonitrile‐butadiene‐styrene (ABS) based composites with a high content of tungsten and bismuth oxide were developed using an innovative process to obtain lead‐free x‐ray shielding materials. ABS was chosen for its good mechanical properties and its widespread availability as a recycled material. The composites underwent flexural tests, Shore D hardness tests, thermogravimetric and morphological analysis, and their x‐ray attenuation properties were determined through numerical simulations and experimental measurements. Despite their high filler content (up to 75 wt%), the composites showed good filler dispersion within the polymeric matrix and maintained their mechanical properties. Across the investigated energy range (50–150 kV), the lead equivalence for x‐ray shielding was achieved with composite plates containing 75 wt% of tungsten and bismuth oxide, at thickness values corresponding to a weight increase of only 29% and 36%, respectively, in comparison to lead. These findings pave the way for a new generation of lead‐free x‐ray shielding materials. Moreover, their mechanical properties, including flexibility for potential application in wearable personal protective equipment, can be tailored by adjusting the filler content. Highlights: High filler content lead‐free ABS composites with WO3 and Bi2O3 were developed.They show good polymer/filler interfacial adhesion and flexural properties.Numerical simulations of their x‐ray shielding properties were performed.Experimental tests with polychromatic sources confirmed good x‐ray attenuation.Results pave the way for the development of new lead‐free x‐ray shielding systems. [ABSTRACT FROM AUTHOR]

In this study, organosilicon compounds were used as modifiers of filaments constituting building materials for 3D printing technology. Polymethylhydrosiloxane underwent a hydrosilylation reaction with styrene, octadecene, and vinyltrimethoxysilane to produce new di- or tri-functional derivatives with varying ratios of olefins. These compounds were then mixed with silica and incorporated into the ABS matrix using standard processing methods. The resulting systems exhibited changes in their physicochemical and mechanical characteristics. Several of the obtained composites (e.g., modified with VT:6STYR) had an increase in the contact angle of over 20° resulting in a hydrophobic surface. The addition of modifiers also prevented a decrease in rheological parameters regardless of the amount of filler added. In addition, comprehensive tests of the thermal decomposition of the obtained composites were performed and an attempt was made to precisely characterize the decomposition of ABS using FT-IR and optical microscopy, which allowed us to determine the impact of individual groups on the thermal stability of the system. [ABSTRACT FROM AUTHOR]

This study surveys the impacts of injection parameters on the deformation rate of the injected flexure hinge made from ABS, PP, and HDPE. The flexure hinges are generated with different filling time, filling pressure, filling speed, packing time, packing pressure, cooling time, and melt temperature. The amplification ratio of the samples between different injection parameters and different plastic types is measured and compared to figure out the optimal one with a high amplification ratio. The results show that the relationship between the input and output data of the ABS, PP, and HDPE flexure hinges at different injection molding parameters is a linear relation. Changing the material or many injection molding parameters of the hinge could lead to a great impact on the hinge's performance. However, changing each parameter does not lead to a sudden change in the input and output values. Each plastic material has different optimal injection parameters and displacement behaviors. With the ABS flexure hinge, the filling pressure case has the greatest amplification ratio of 8.81, while the filling speed case has the lowest value of 4.81. With the optimal injection parameter and the input value of 105 µm, the ABS flexure hinge could create a maximum average output value of 736.6 µm. With the PP flexure hinge, the melt temperature case achieves the greatest amplification ratio of 6.73, while the filling speed case has the lowest value of 4.1. With the optimal injection parameter and the input value of 128 µm, the PP flexure hinge could create a maximum average output value of 964.8 µm. The average amplification ratio values of all injection molding parameters are 6.85, 5.41, and 4.01, corresponding to ABS, PP, and HDPE flexure hinges. Generally, the ABS flexure hinge has the highest amplification ratios, followed by the PP flexure hinge. The HDPE flexure hinge has the lowest amplification ratios among these plastic types. With the optimal injection parameter and the input value of 218 µm, the HDPE flexure hinge could create a maximum average output value of 699.8 µm. The results provide more insight into plastic flexure hinges and broaden their applications by finding the optimal injection parameters and plastic types. [ABSTRACT FROM AUTHOR]

The development of additive manufacturing (AM) technologies has significantly advanced fabrication capabilities, yet achieving optimal surface quality and mechanical properties in end-use products is challenging. The primary objective of this study is to improve specific characteristics of 3D-printed components by employing a chemical post-processing technique including acetone. This technique is specifically applied to acrylonitrile butadiene styrene (ABS) material, utilizing a customized mechanical cold-vapor system. A complete investigation was undertaken to assess the effects of treatment on many factors, such as temperature, solvent volume, and exposure duration, on the tensile strength, physical dimensions, and mass of the ABS samples. Acetone post-processing has notably improved tensile strength, influenced by treatment duration and temperature and has led to dimensional changes such as a slight length reduction and increases in width and thickness. Furthermore, the mass of the samples exhibited variability upon acetone treatment, which was shown to be dependent on both the ambient temperature and the duration of solvent exposure. The tensile strength was assessed under various conditions, showing a significant enhancement at higher temperatures and longer exposure times. These results, demonstrating smoother surfaces and a tensile strength increase of up to 20% at 65 °C, underscore the efficacy of our techniques in modifying the mechanical and physical properties of 3D-printed ABS components. This innovative approach provides valuable insights into the relationship between post-processing conditions and ABS properties, enriching the body of knowledge in AM technology. [ABSTRACT FROM AUTHOR]

Multiwall carbon nanotubes (MWCNTs) can be spread out in acrylonitrile butadiene styrene (ABS) using a twin‐screw micro‐compounding extruder. It can significantly improve the mechanical properties of 3D‐printed objects. Dispersed MWCNTs in pure ABS to develop the nanocomposites through a two‐time micro compounding extruding process. 3D printed filaments with a diameter of 1.75 mm have been prepared by processing the acquired composite structure through a filament extruder. The mechanical and other properties of 3D printed pure ABS and 1, 2, and 3 wt.% of the fused deposition modeling (FDM) process were studied for MWCNTs/ABS composites. Compared with pure ABS, the tensile and thermal properties were significant for 1, 2, and 3 wt.% of MWCNTs/ABS composites. Fourier transform infrared spectroscopy (FTIR), X‐ray diffraction (XRD), thermogravimetric analysis (TGA), and scanning electron microscopy (SEM) were also analyzed for 0, 1, 2, and 3 wt.% MWCNTs/ABS composites. Additive manufacturing (AM) processes have recently been emphasized for their applications in electronics, aerospace, biomedical, and automobile engineering. [ABSTRACT FROM AUTHOR]

The purpose of this study is to determine the effect of manufacturing conditions on the mechanical properties and structure of ABS parts. Two sets of samples with the same geometric characteristics were produced by Fused Deposition Modelling (FDM) and injection molding (IM). The molding pressure and cooling rate were found to have a significant effect on shaping the mechanical properties and structure of ABS products. The manufacturing method and adopted process parameters have a significant impact on the degree of packing of macromolecules in the volume of the product, and thus determine its density. Selected mechanical properties were determined and compared with their specific gravity. The research was carried out using tools and machines, i.e. injection molds of unique design and standard measuring stations. Tensile and bending strengths and Young's modulus were related to the density of products obtained under different process conditions and having gradient and solid structures. The results provide useful information for engineers designing products using FDM technology. Relating tensile and flexural strength and Young's modulus to the specific gravity of the product. It was found that the value of product properties is closely related to various process conditions, which further provides a true description of the products. [ABSTRACT FROM AUTHOR]