Optimizing process parameters to enhance mechanical properties of 3D-printed fiberglass-reinforced onyx polymer.

Shafique, Naumaan; Khan, Zarak; Khan, Mushtaq; Younas, Muhammad; Saharudin, Mohd Shahneel

Abstract

Fused Deposition Modeling (FDM) is widely used for custom manufacturing but has limitations in strength for load-bearing applications. This study explores the optimization of mechanical properties for lightweight, cost-effective components using continuous fiber reinforcement. ONYX polymer, reinforced with continuous fiberglass, was printed using the Markforged® Mark Two dual nozzle 3D printer. A Design of Experimentation (DoE) based on a Taguchi L9 array was used, varying fiberglass content (10%, 20%, 30%), infill densities (30%, 40%, 50%), and pattern types (hexagonal, rectangular, Triangular). The results show that increasing fiberglass content, infill density, and using a rectangular pattern enhanced mechanical properties, with a 30% fiberglass addition achieving a 4.743-fold increase in Izod impact energy. The highest mechanical performance was obtained with 30% fiberglass, 50% infill density, and a rectangular pattern, yielding an impact energy of 1576.778 J/m, compressive strength of 29.486 MPa, and Shore D hardness of 68.135 HD.

Citation

SHAFIQUE, N., KHAN, Z., KHAN, M., YOUNAS, M. and SAHARUDIN, M.S. 2025. Optimizing process parameters to enhance mechanical properties of 3D-printed fiberglass-reinforced onyx polymer. Journal of manufacturing and materials processing [online], 9(4), article number 108. Available from: https://doi.org/10.3390/jmmp9040108

• Journal Article Type: Article
• Acceptance Date: Mar 13, 2025
• Online Publication Date: Mar 26, 2025
• Publication Date: Apr 30, 2025
• Deposit Date: Mar 29, 2025
• Publicly Available Date: Apr 15, 2025
• Journal: Journal of manufacturing and materials processing
• Electronic ISSN: 2504-4494
• Publisher: MDPI
• Peer Reviewed: Peer Reviewed
• Volume: 9
• Issue: 4
• Article Number: 108
• DOI: https://doi.org/10.3390/jmmp9040108
• Keywords: Fiberglass and ONYX polymer; Additive manufacturing; Multi-objective optimization
• Public URL: https://rgu-repository.worktribe.com/output/2762291