Characterizations of 3D-printed copper-reinforced ABS polymer composites fabricated by twin-screw extruder

Abstract

Fused Deposition Modelling (FDM) is an affordable 3D printing technique for processing thermoplastics and composites. Widely used for its ability to create intricate products at low cost, FDM has gained popularity in additive manufacturing. To enhance the mechanical, thermal, and electrical properties of ABS polymers, copper particles were added at varying proportions. This study focuses on developing a copper-reinforced ABS polymer composite filament using a twin-screw extruder and fabricating Cu-ABS composites via FDM. Copper particles with a 200 Mesh size were used, and feedstock filaments were created with compositions of 99% ABS-1% Copper, 97.5% ABS-2.5% Copper, 95% ABS-5% Copper, 92% ABS-8% Copper, and 90% ABS-10% Copper. DSC thermal characterization and electrical conductivity tests revealed that the 90% ABS-10% Copper composite was optimal. The ultimate compressive strength and hardness were tested for the 90% ABS-10% Copper composition using Taguchi's L9 orthogonal array and Design of Experiments (DOE). Analysis of Variance (ANOVA) identified key process parameters. The highest compressive strength and hardness values were achieved with printing parameters of 230°C (printing temperature), 0.20 mm (layer height), and a specific infill pattern. These findings provide valuable insights for developing parts with enhanced mechanical, electrical, and thermal properties, offering potential applications in industries such as automotive, aerospace, and electronics.