Compressive Properties of Additively Manufactured Metal-Reinforced PLA and ABS Composites

The development of multi-material filaments has enabled fused filament fabrication-based additive manufacturing to address demand for high-performance lightweight multifunctional components. In this study, polylactic acid (PLA) and acrylonitrile butadiene styrene processing–structure–property)-based filaments with metallic reinforcements of magnetic iron (MI), stainless steel (SS), bronze (Br), copper (Cu), Bismuth (Bi), and Tungsten (W) were investigated to elucidate their complex processing–structure–property relationships. The microstructure of 3D-printed materials were characterized by microscopy and analyzed to determine the metal cross-sectional area percentage and the relationship between metal reinforcement, the polymer matrix, and porosity. Compression testing was conducted in directions parallel and perpendicular to the build direction in order to evaluate the effect of orientation and metal reinforcement on the mechanical properties. Three-dimensional-printed specimens experienced either fracture through print layers or layer-wise interfacial rupture for loads applied perpendicular and parallel to the print layers, respectively. A dependence of yield strength on loading orientation was observed for Br-PLA, Cu-PLA, SS-PLA, Bi-ABS, and W-ABS; however, MI-PLA and pure ABS specimens did not exhibit this sensitivity. Metal reinforcement also influenced the magnitude of compressive yield strength, with MI-PLA and SS-PLA demonstrating increased strength over Br-PLA and Cu-PLA, while ABS demonstrated increased strength over Bi-ABS and W-ABS. These results demonstrate the importance of considering orientation in printing and applications, the trade-off between various metallic reinforcements for added multifunctionality, and the potential of these tailored polymer composites for novel 3D-printed structures.