Effects of Process Parameters on the Mechanical Properties and Microstructure of Additively Manufactured Carbon Black Particles-Reinforced Thermoplastic Polyurethane Composite Samples

Hira F, Asif M, Ullah H, Khan I, Hussain G, Amir M, Alkahtani M (2025)

Publication Type: Journal article

Publication year: 2025

Journal

Polymers MDPI

Book Volume: 17

Article Number: 426

Journal Issue: 3

DOI: 10.3390/polym17030426

Abstract

Additive manufacturing (AM) techniques make fabricating complex designs, prototypes, and end-user products possible. Conductive polymer composites find applications in flexible electronics, sensor fabrication, and electrical circuits. In this study, thermoplastic polyurethane (TPU)-based conductive polymer composite samples were fabricated via fused filament fabrication (FFF). The effects of three important process parameters, including infill density (ID), layer thickness (LT), and fan speed (FS), on various mechanical properties (tensile and compressive properties) were investigated. It was observed that all the considered process parameters affect the mechanical properties, and they are significant parameters, as per the analysis of variance (ANOVA). From scanning electron microscopy (SEM) and optical microscopy, various combinations of parameters such as low ID, high LT, and high FS resulted in the formation of defects such as voids, cracks, and warping, which resulted in low mechanical properties. Finally, process parameter optimization was performed, resulting in a conductive polymer composite with the best possible combination of mechanical properties at high ID, low LT, and medium FS.

Involved external institutions

Shaheed Benazir Bhutto Women University PK Pakistan (PK) University of Peshawar PK Pakistan (PK) Sarhad University of Science and Information Technology / جامعہ سرحد PK Pakistan (PK) University of Engineering and Technology Peshawar / انجینئرنگ اینڈ ٹیکنالوجی پشاور یونیورسٹی PK Pakistan (PK) University of Bahrain (UoB) / جامعة البحرين BH Bahrain (BH) King Saud University (KSU) / جامعة الملك سعود‎‎ SA Saudi Arabia (SA)

How to cite

APA:

Hira, F., Asif, M., Ullah, H., Khan, I., Hussain, G., Amir, M., & Alkahtani, M. (2025). Effects of Process Parameters on the Mechanical Properties and Microstructure of Additively Manufactured Carbon Black Particles-Reinforced Thermoplastic Polyurethane Composite Samples. Polymers, 17(3). https://doi.org/10.3390/polym17030426

MLA:

Hira, Fatima, et al. "Effects of Process Parameters on the Mechanical Properties and Microstructure of Additively Manufactured Carbon Black Particles-Reinforced Thermoplastic Polyurethane Composite Samples." Polymers 17.3 (2025).

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