Graphene-Reinforced PETG Composites: Microstructural Insights and Mechanical Evaluation Using Fused Deposition Modelling

This study reports on the development of a PETG composite incorporating graphene material, aiming to enhance microstructural and mechanical performance without compromising processability. The hybrid functional material demonstrates significantly improved tensile strength, load-bearing capacity, and fracture behavior. Using Fused Deposition Modeling (FDM), composites were fabricated with varying graphene content (0.02, 0.2, and 0.4 wt%), nozzle temperatures (245°C, 255°C, and 265°C), and build orientations (H1, H2, V1). The tensile testing results indicate that optimized parameters, particularly higher temperatures and horizontal orientations, lead to superior mechanical properties. Scanning Electron Microscopy (SEM) revealed a coarse, fibrous fracture surface with well-dispersed graphene nanoplatelets, confirming ductile failure and moderate interfacial adhesion. In addition, directional dependency in material properties makes orientation a key factor, particularly in load-bearing applications. Findings suggest that a horizontal build orientation generally offers superior performance, emphasizing the need for careful orientation selection to ensure structural integrity and optimize functionality in 3D-printed parts. Overall, the study underscores the potential of PETG/graphene composites in engineering applications, where tuneable properties and manufacturability are both critical.