Abstract

Abstract: Nylon is a thermoplastic polymer that possesses impressive strength, durability, and low friction properties, making it a commonly used material in engineering applications. The automotive industry utilizes Nylon for manufacturing engine components, brake systems, and fuel tanks. Despite its strength and durability, Nylon may not be suitable for high-load applications that require stronger materials such as metals or composites [1]. However, Onyx, which is Nylon infused with micro carbon fibers, has enhanced strength properties compared to pure Nylon due to its unique micro-carbon reinforcement. Moreover, adding continuous fiber reinforcement to Onyx results in a lightweight and robust material. Fused Deposition Modelling (FDM) technology using a Continuous Fiber Composite 3D Printer can fabricate Onyx components with continuous strand fibers, providing a staggering level of strength [2]. This material combination has the potential to replace metal tooling for aerospace, automotive, and wind energy applications. Nevertheless, the behaviour of these composites under specific loading conditions is not yet fully understood [3]. Therefore, this study employs FDM technology to manufacture components using Onyx with varying content of continuous fiberglass (FG). The study utilized FDM technology to manufacture components made of Onyx, a type of Nylon infused with 20% chopped carbon fiber. The Mark TwoTM Continuous Fiber Composite 3D Printer was employed to create tensile samples according to ASTM D638 standard. Overall, the findings suggest that continuous FG played a vital role in enhancing the tensile strength for onyx components. The microstructural defects observed on the outer and fractured interfaces, such as air gaps and voids, are directly related to the tensile strength results. Therefore, it is crucial to address these printing problems and defects to enhance the strength and accuracy of the samples. Moreover, the poor bonding between the matrix and fibers, as evidenced by the fibers being pulled out during the test, needs improvement to enhance overall strength.