Mechanical properties and numerical simulation of FDM 3D printed PETG/carbon composite unit structures

Carbon fibers (CFs) were used as reinforcement in developing a polyethylene terephthalate glycol (PETG)-based polymer composite using the fused deposition modeling (FDM) 3D printing technique. The influence of CF and process factors (infill percentage, layer thickness, infill pattern) were studied by measuring the prepared polymer composite's tensile, flexural, and compressive properties. The innovative work that was carried out for this study and the tests that were performed revealed that it is difficult to predict the position of the specimen break area before a test. The PETG-reinforced polymer only showed enhanced flexural and tensile strength at a layer thickness of 0.25 mm and a maximum infill percentage of 20% for a solid structural design. Compressive strength improved in reinforced PETG hexagonal and circle structures. The confirmation of the numerical modeling applied to determine the mechanical properties of PETG for FDM additive manufacturing is one of the goals suggested in this research, along with a comparison of experimental and computational data. Scanning electron microscopy examination of the fractured sample surfaces revealed various fracture mechanisms and morphologies for the materials tested. The research found that the 3D-printed composite could further expand the application of PETG as an engineering material.