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Fused deposition modeling (FDM) is utilized to fabricate continuous fiber‐reinforced thermoplastic composites (CFRTPCs) and can be considered an alternative to conventional processes. In present study, the specimens are 3D printed in Markforged Mark Two composite 3D printer by considering Onyx as matrix material and fiberglass as reinforcing material. Thermal gravimetric analysis (TGA) and Fourier transform infrared spectroscopy (FTIR) of Onyx and fiberglass materials are done to investigate their thermal stability and composition. The effect of infill pattern and fiber orientation on tensile and drop impact properties are examined. The TGA results show that the initial decomposition in Onyx is higher compared to fiberglass due to more evaporation of moisture content in Onyx. The FTIR analysis confirmed that the spectrum for both materials is same within the range of wave number from 4000 to 1500 cm−1. The tensile test results represent that the specimen with triangular infill pattern and 0°/90° fiber orientation resulted in maximum tensile strength of 148.01 MPa and the drop impact test results showed that the triangular infill pattern with 0°/90° fiber orientation absorbs maximum impact energy which is 14.90% and 8.98% higher compared to honeycomb and rectangular pattern respectively. Further, the fracture behavior study is carried out based on the optical images of fractured specimens. [ABSTRACT FROM AUTHOR]

As an additive manufacturing (AM) technology, fused deposition modeling (FDM) is widely used to fabricate highly complex components. Polymer components fabricated by FDM technique have weak mechanical properties. To enhance the mechanical properties, 3D printing of polymer composites is done by reinforcing particles, nanomaterials, short and continuous fibers into thermoplastic polymers. The thermal, flame retardant, and impact properties of a continuous kevlar fiber‐reinforced onyx 3D‐printed composite are investigated in this study. Additionally, the effect of fiber arrangement and orientation (0°, 90°, 0°/90°, and +45°/−45°) on the impact strength of 3D‐printed composites have been investigated. The impact strength of the 3D‐printed composite specimens was determined using izod impact testing. It was found that specimens with fiber arrangement having fiber and matrix layer configuration as 21O|20K|20O|20K|21O have a higher impact strength and specimens with fiber arrangement as 31O|40K|31O have lower impact strength. Furthermore, specimen 3D printed with a unidirectional 0° fiber angle had the highest impact strength, while specimen 3D printed with a unidirectional 90° fiber angle had the lowest impact strength. Furthermore, flammability tests and thermogravimetric analysis were performed to investigate the flame retardant and thermal properties of 3D‐printed composites. Morphological study of onyx and kevlar fiber filament was also done using scanning electron microscope (SEM). [ABSTRACT FROM AUTHOR]