Authors: Deepak Dawar, Om Prakash Sondhiya
Abstract: The increasing demand for lightweight, high-strength, and environmentally sustainable materials has accelerated the adoption of additive manufacturing technologies in engineering applications. Among various additive manufacturing techniques, Fused Deposition Modelling (FDM) has gained significant attention due to its cost-effectiveness, design flexibility, and capability to fabricate complex geometries. Polylactic Acid (PLA) is one of the most extensively used thermoplastic materials in FDM because of its biodegradability, low processing temperature, and excellent dimensional stability. However, the relatively low mechanical strength and poor wear resistance of neat PLA restrict its utilization in structural and tribological applications. To overcome these limitations, carbon fibre reinforcement has emerged as a promising approach for improving the performance of PLA-based composites. Carbon fibres possess high specific strength, excellent stiffness, low density, and superior wear resistance, making them suitable reinforcements for polymer matrices. The present research investigates the influence of varying carbon fibre content on the mechanical behaviour and tribological performance of 3D printed PLA composites fabricated using an IQ200 FDM printer. PLA composites containing 0 wt.%, 5 wt.%, 10 wt.% and 15 wt.% carbon fibre are considered for investigation. Mechanical characterization includes tensile strength, flexural strength, impact strength, and hardness evaluation according to ASTM standards. Wear behaviour is analysed using a pin-on-disc tribometer under varying loading conditions. Scanning Electron Microscopy (SEM) is proposed to examine fracture surfaces and wear tracks for understanding failure mechanisms and fibre-matrix interactions. Furthermore, Response Surface Methodology (RSM) and Artificial Neural Network (ANN) modelling are incorporated to establish predictive relationships between carbon fibre content, printing parameters, and performance responses. The anticipated outcomes include enhanced tensile strength, increased stiffness, reduced wear rate, and improved dimensional stability. The findings are expected to contribute toward the development of advanced lightweight composite materials for automotive, aerospace, biomedical, and industrial applications.
