The Enhancing Influence of Process Parameters on Acrylonitrile Butadiene Styrene Composites Reinforced with Microcrystalline Cellulose

This study investigates the effects of different synthesis parameters of Acrylonitrile Butadiene Styrene/Microcrystalline Cellulose (ABS)/(MCC) composites on their physical, mechanical, and morphological properties. Composites were fabricated using a twin-screw extruder followed by hot pressing, with variations in the MCC volume fraction (0–8 vol%), screw speeds (10–20 rpm), and extrusion temperatures (150–170 ℃). Density and flexural strength tests were conducted in accordance with ASTM standards, and the surface morphology was analyzed using Scanning Electron Microscopy (SEM). The results showed that incorporating 2–4 vol% of MCC improved both density and flexural strength by reducing voids and enhancing interfacial bonding. However, higher MCC contents led to particle agglomeration and diminished performance. A lower screw speed of 10 rpm facilitated better filler dispersion and stronger interfacial adhesion, yielding the highest flexural strength. Conversely, excessive screw speeds and elevated extrusion temperatures caused filler degradation, matrix shrinkage, and void formation, negatively impacting composite integrity. These findings demonstrate that careful optimization of filler content and processing parameters is essential to produce high-performance ABS/MCC composites with improved structural and mechanical characteristics.