Effects of SiC content and printing speed on mechanical characteristics of composites fabricated via a hybrid process

The automotive and aviation industries, in particular, demand strong components such as supports and fasteners, which require rapid and cost-effective production. As a consequence of their layered composition, ABS parts produced by 3D printing frequently exhibit both prolonged production times and inadequate mechanical strength. However, the utilisation of internal cavity composites has been demonstrated to enhance strength. Silicon carbide-reinforced polymer composites have been identified as a promising candidate. In the present study, composite materials were produced by injecting 10%, 15% and 20% silicon carbide-reinforced epoxy materials into the interior of ABS parts fabricated at printing speeds of 50-70 and 90 mm/s and with an internal structure of 85% voids by vacuum-assisted injection method using the innovative design of additive manufacturing and the fast mass production advantage of injection moulding method. Tensile and bending tests were carried out to ascertain the mechanical characteristics and scanning electron microscopy analyses were conducted. The study revealed that the maximum tensile strength of 27.60 MPa and the maximum flexural strength of 54.42 MPa were observed in the sample printed at a speed of 90 mm/s and containing 10 wt.% SiC. The overarching objective of the present study is to enhance the performance of composite materials produced by hybrid manufacturing methodologies in industrial applications.