Investigating physical and mechanical properties of alumina/acrylonitrile butadiene styrene composites manufactured by fused deposition modeling

Abstract In recent years, 3D printing technologies or additive manufacturing have gained significant attention in research and other industries. Among the various 3D printing techniques, fused deposition modeling has been the most widely adopted. This study focused on developing composite filaments by incorporating acrylonitrile butadiene styrene (ABS) with different volume percentages of aluminum oxide (alumina). The mechanical and physical properties of parts printed with these composite filaments were thoroughly evaluated. Tensile testing revealed that increasing the alumina content led to a reduction in tensile strength. At 20 vol%, tensile strength dropped by 72%. A heat deflection temperature (HDT) test indicated an 11% reduction in HDT, likely due to the defective composite structure. Thermogravimetric analysis test demonstrated improved thermal stability as alumina content increased. Linear shrinkage was measured in three directions, revealing anisotropic shrinkage patterns. Hardness tests were conducted, and a decrease was observed when the polymer was filled with alumina. Finally, the warpage was reduced by 91% as alumina content increased to 20%. Highlights Alumina/ABS composite filaments were manufactured and 3D‐printed very well. The void content in composite samples increases with alumina powders. The mechanical properties of 3D‐printed composite parts were decreased The alumina powder improves the warpage issues in 3D‐printed parts.