Fused Deposition Modeling Technology Research Articles

Optimization of Production Parameters for Impact Strength of 3D-Printed Carbon/Glass Fiber-Reinforced Nylon Composite in Critical ZX Printing Orientation

Additive manufacturing (AM) methods are increasingly being adopted as an alternative for mass production. In particular, Fused Deposition Modeling (FDM) technology is leading the way in this field. However, the adhesion of the layers in products produced using FDM technology is an important issue. These products are particularly vulnerable to forces acting parallel to the layers and especially to impact strength. Most products used in the industry have complex geometries and thin walls. Therefore, solid infill is often required in production, and this production must take place in the ZX orientation. This study aims to optimize the impact strength against loads acting parallel to the layers (ZX orientation) of PA6, one of the most widely used materials in the industry. This orientation is critical in terms of mechanical properties, and the mechanical characteristics are significantly lower compared to other orientations. In this study, filaments containing pure PA6 with 15% short carbon fiber and 30% glass fiber were utilized. Additionally, the printing temperature, layer thickness and heat treatment duration were used as independent variables. An L9 orthogonal array was employed for experimental design and then each experiment was repeated three times to conduct impact strength tests. Characterization, Taguchi optimization, and factor analyses were performed, followed by fracture surface characterization by SEM. As a result, the highest impact strength was achieved with pure PA6 at 8.9 kJ/m2, followed by PA6 GF30 at 8.1 kJ/m2, and the lowest impact strength was obtained with PA6 CF15 at 6.258 kJ/m2. Compared to the literature and manufacturer datasheets, it was concluded that the impact strength values had significantly increased and the chosen experimental factors and their levels, particularly nozzle temperature, were effective.

Mechanical, thermal, and microstructure analysis of 3D printed polyolefin elastomer-acrylonitrile butadiene styrene blends for tunable mechanical properties

Fused Deposition Modeling (FDM) has emerged as a cost-effective and user-friendly technique that has garnered significant attention in recent years. However, challenges persist when printing soft materials using FDM technology. This study proposes a solution by blending a soft polyolefin elastomer (POE) with a stiffer material, acrylonitrile butadiene styrene (ABS). A comprehensive experimental investigation utilizing a direct pellet printing method was conducted to 3D print POE-ABS blends in various ratios (10%, 30%, and 50% ABS content). The study encompassed material preparation, 3D printing, SEM (Scanning Electron Microscopy) analysis, Dynamic Mechanical Thermal Analysis (DMTA), uniaxial tensile testing, and compression testing to assess the mechanical properties and energy absorption capabilities of the 3D printed blends. The results of the DMTA showed that the blends with a higher amount of ABS have a larger area under the Tan δ curve, indicating their ability to absorb more energy. The SEM images revealed that as the proportion of ABS increases, the gaps between layers and beads become smaller. The mechanical properties of the pure printed POE, such as its elongation at break and tensile strength, were 2138% and 2.83 MPa, respectively. However, as the ABS content increased, the samples exhibited more rigid behavior, with a final transition to 50/50 ratio resulting in 9.4 MPa tensile strength and 160% elongation at break. The energy absorption test demonstrated that the sample with 30% ABS content has the highest energy absorption capability among all the tested samples. This research underscores the potential of blending soft and stiff materials to tailor properties for additive manufacturing applications, emphasizing the significance of material composition in achieving desired mechanical performance, printability, and functionality in printed objects.

Integration of nanomaterials in FDM for enhanced surface properties: Optimized manufacturing approaches

This article presents a comprehensive review of advanced techniques for integrating nanomaterials into fused deposition modeling (FDM) processes, addressing prevalent challenges such as limited surface quality and wear resistance in traditional FDM-printed parts. The integration of nanomaterials offers potential solutions to these issues by enhancing surface properties. This review explores key methodologies, including direct nanoparticle mixing with polymer filaments, in-situ polymerization, and surface coating techniques, and demonstrates their impact on improving surface roughness and wear resistance. Specifically, nanomaterial-enhanced composites achieve up to a 30% reduction in surface roughness and a 40% improvement in wear resistance compared to conventional materials. To optimize manufacturing processes, we apply the Taguchi method to identify critical process parameters such as extrusion temperature, print speed, layer thickness, and nanoparticle concentration that influence surface properties. Our simulations and analysis of variance (ANOVA) indicate that optimal settings can enhance surface quality by 25% and improve wear resistance by 35%. The proposed methodologies and theoretical framework lay the groundwork for experimental validation, which will involve testing the optimized parameters and assessing their practical impact. This research advances the field of additive manufacturing by providing novel insights into nanomaterial integration, paving the way for improved FDM technology with applications spanning aerospace, biomedical engineering, and beyond. The findings contribute significantly to overcoming existing limitations and enhancing the performance of FDM-printed parts.

RSM-BASED STATISTICAL APPROACH TO ENHANCE THE COMPRESSIVE PERFORMANCE OF ABS P400 PARTS FABRICATED VIA FDM TECHNOLOGY

This research investigates the performance of ABS P400 parts under compressive loading. These ABS P400 parts are fabricated by fused deposition modeling (FDM) process using omnidirectional printing. The effects of three critical parameters, raster angle (A), air gap (B), and raster width (C), each at three different levels, were analyzed on three different performance measures, i.e. total deformation up to failure ([Formula: see text]) measured in %, maximum energy ([Formula: see text]) in MJ/m3 and break energy ([Formula: see text]) in MJ/m3. Results of experimentations were analyzed using analysis of variance (ANOVA), perturbation curve and 3D surface plots. The research established the anisotropic nature, durability and less brittleness of the FDM fabricated ABSP400 part, which leads to lower strength and also influence the energy absorbing behavior while deformation under compression. Complex relationships were exhibited between the chosen parameters and studied measures. It was also observed that [Formula: see text] is noticeable due to less brittleness of ABS P400 however, [Formula: see text] and [Formula: see text] vary in a contradictory fashion with changes in process parameters. The models were validated using normality plots. Multi-objective optimization was done using the desirability approach to determine the optimal combination of FDM process parameters for optimum responses. The desirability result showed that the optimized input parameter is [Formula: see text][Formula: see text]mm, and [Formula: see text][Formula: see text]mm which yield maximized optimum responses as [Formula: see text]%, [Formula: see text][Formula: see text]MJ/m3, and [Formula: see text][Formula: see text]MJ/m3. The work not only reflects the effect of three FDM parameters on the total deformation up to failure ([Formula: see text] in %) but, in addition, energy absorption behavior of FDM parts under compression is also investigated. The study on the behavior of energy at ultimate stress or ultimate load and breaking stress or breaking load were rarely investigated in earlier research which reflects the novelty of our research.

Development and evaluation of a surgical 3D simulation model on submental flap surgery training.

The purpose of the present study was to design and assess a 3D simulation model for submental flap surgery in training oral and maxillofacial surgery (OMFS) residents. This quasi-experimental study involved a total of 20 OMFS residents attending and was conducted from September 2023 to December 2023. A 3D submental flap surgical phantom was designed using Mimics V.21 software and printed using fused deposition modeling technology. Participants were first tested on their knowledge of submental flap surgery before being randomly assigned to experimental or control groups. The experimental group received a lecture and demonstration using the developed phantom, while the control group had traditional lecture education only. Afterward, the same test was administered to all participants post-training. Pre- and post-test scores were calculated and compared between the two groups. p-Value<0.05 was considered statistically significant. The average pre-intervention test scores in the control and experimental group, were 2.5±1.43 and 3±0.816, respectively (p=0.35). Post-intervention, the experimental group exhibited significantly higher exam scores compared to the group who had only received academic lecture training (6.9±0.87 vs. 4.9±0.99) (p<0.001). Irrespective of the applied teaching method, both groups showed a significant increase in exam scores after receiving submental flap training (p<0.001 for both groups, paired-sample t-test). The use of the developed submental flap phantom model significantly improved OMFS residents' test scores and knowledge of the surgical technique, suggesting its potential integration into the conventional resident training curriculum.

Powder Loading Effects on the Physicochemical and Mechanical Properties of 3D Printed Poly Lactic Acid/Hydroxyapatite Biocomposites.

This study presents the physicochemical and mechanical behavior of incorporating hydroxyapatite (HAp) with polylactic acid (PLA) matrix in 3D printed PLA/HAp composite materials. Effects of powder loading to the composition, crystallinity, morphology, and mechanical properties were observed. HAp was synthesized from locally sourced nanoprecipitated calcium carbonate and served as the filler for the PLA matrix. The 0, 5, 10, and 15 wt. % HAp biocomposite filaments were formed using a twin-screw extruder. The resulting filaments were 3D printed in an Ultimaker S5 machine utilizing a fused deposition modeling technology. Successful incorporation of HAp and PLA was observed using infrared spectroscopy and X-ray diffraction (XRD). The mechanical properties of pure PLA had improved on the incorporation of 15% HAp; from 32.7 to 47.3 MPa in terms of tensile strength; and 2.3 to 3.5 GPa for stiffness. Moreover, the preliminary in vitro bioactivity test of the 3D printed PLA/HAp biocomposite samples in simulated body fluid (SBF) indicated varying weight gains and the presence of apatite species’ XRD peaks. The HAp particles embedded in the PLA matrix acted as nucleation sites for the deposition of salts and apatite species from the SBF solution.

Mechanical properties of sandwich structures with different webs enhanced by filling polyurethane foam and encasing rectangular tube

In this paper, sandwich structures with different forms of webs are prepared by fused deposition modeling technology. The effect of the concave and convex shape of the web and its position on the mechanical properties of sandwich structure is explored. The different constraints are implemented on the sandwich structure by encasing thin-walled rectangular tube externally and filling polyurethane foam internally, respectively. Then, a sandwich structure with both rectangular tube and polyurethane foam, namely, rectangular tube encased foam-filled sandwich structure is proposed to synergistically enhance the sandwich structure. The encased rectangular tube strengthens the sandwich structure and avoids the failure of the whole structure under small strain. Rectangular tube encased foam-filled sandwich structure reduces the oscillation in the plateau stage of compressive curve and has the highest mechanical properties.

On the Fused Deposition Modelling of Personalised Bio-Scaffolds: Materials, Design, and Manufacturing Aspects.

Bone tissue engineering (BTE) is an important field of research, essential in order to heal bone defects or replace impaired tissues and organs. As one of the most used additive manufacturing processes, 3D printing can produce biostructures in the field of tissue engineering for bones, orthopaedic tissues, and organs. Scaffold manufacturing techniques and suitable materials with final structural, mechanical properties, and the biological response of the implanted biomaterials are an essential part of BTE. In fact, the scaffold is an essential component for tissue engineering where cells can attach, proliferate, and differentiate to develop functional tissue. Fused deposition modelling (FDM) is commonly employed in the 3D printing of tissue-engineering scaffolds. Scaffolds must have a good architecture, considering the porosity, permeability, degradation, and healing capabilities. In fact, the architecture of a scaffold is crucial, influencing not only the physical and mechanical properties but also the cellular behaviours of mesenchymal stem cells. Cells placed on/or within the scaffolds is a standard approach in tissue engineering. For bio-scaffolds, materials that are biocompatible and biodegradable, and can support cell growth are the ones chosen. These include polymers like polylactic acid (PLA), polycaprolactone (PCL), and certain bioglass or composite materials. This work comprehensively integrates aspects related to the optimisation of biocompatible and biodegradable composites with the low cost, simple, and stable FDM technology to successfully prepare the best designed composite porous bone-healing scaffolds. FDM can be used to produce low-cost bone scaffolds, with a suitable porosity and permeability.

3D Printer Nozzle Structure Form Optimal Structural Analysis

The most representative technology of 3D printing is fused deposition modeling (FDM). To improve the printing accuracy of FDM technology, this paper first takes the outlet diameter, angle of convergence, and rectifier section length of the nozzle as the influencing factors. It takes the melt outlet speed stability, viscosity, and outlet pressure as the indexes to design the orthogonal test. Then, COMSOL Multiphysics fluid–solid coupling simulation was used to simulate and analyze the structural characteristics of the 3D printer nozzle, and the range analysis method was used to analyze the data. Finally, the two-phase flow combination was used to simulate the morphological characteristics of the melt flowing out of the nozzle. The results show that the simulation results of the two materials are similar. As the nozzle diameter decreases, the melt pressure decreases, the velocity increases, and the viscosity decreases. For PLA wire rods, the optimal structure of the nozzle is that the outlet diameter is 0.2 mm, the rectifier section length is 1.5 mm, and the angle of convergence is 60°. For ABS wire, the optimum structure of the nozzle is that the outlet diameter is 0.2 mm, the rectifier section length is 1.5 mm, and the angle of convergence is 30°. The nozzle outlet diameter is inversely proportional to the printing accuracy for ABS and PLA materials. The research results provide a theoretical reference for optimizing the nozzle structure for 3D printing.

Advancements in Fused Deposition Modeling for Aerospace: Optimizing Lightweight and High- Strength Components

Fused Deposition Modeling (FDM) has emerged as a pivotal technology in aerospace manufacturing, enabling the creation of lightweight and high-strength components. Recent advancements in FDM materials, process optimization, and design methodologies have significantly enhanced its applicability in producing aerospace parts that meet stringent performance criteria. This paper reviews the latest developments in FDM technology, focusing on material innovations, structural optimization techniques, design for additive manufacturing and practical applications in the aerospace sector. Key advancements include the use of high-performance thermoplastics, carbon fiber composites, and hybrid materials, as well as improved printing techniques that reduce defects and enhance mechanical properties. The potential of FDM to revolutionize aerospace manufacturing through cost- effective and efficient production of complex geometries is explored, highlighting ongoing research and future directions in this dynamic field.

Modeling and Strength Calculations of Parts Made Using 3D Printing Technology and Mounted in a Custom-Made Lower Limb Exoskeleton.

This study is focused on the application of 3D-printed elements and conventional elements to create a prototype of a custom-made exoskeleton for lower limb rehabilitation. The 3D-printed elements were produced by using Fused Deposition Modeling technology and acrylonitrile butadiene styrene (ABS) material. The scope of this work involved the design and construction of an exoskeleton, experimental testing of the ABS material and numerical research by using the finite element method. On the basis of the obtained results, it was possible to deduce whether the load-bearing 3D-printed elements can be used in the proposed mechanical construction. The work contains full data of the material models used in FEM modeling, taking into account the orthotropic properties of the ABS material. Various types of finite elements were used in the presented FE models. The work is a comprehensive combination of material testing issues with the possibility of implementing the obtained results in numerical strength models of machine parts.

Effect of manufacturing process parameters on the compression and energy absorption properties of 4D-printed deformable honeycomb structure

Four-dimensional-printed deformable honeycombs can produce pro-programmed shape deformation and different properties under external stimuli, and the manufacturing process parameters are the dominant factors affecting the microstructure and properties of the manufactured honeycomb structures. Although many researchers have investigated the effects of manufacturing process parameters on the mechanical properties of printed materials, there is still a lack of research on the relationship between manufacturing process parameters and properties of honeycomb structures. Therefore, a novel honeycomb structures which has two configurations under temperature stimuli is proposed, and the optimum manufacturing processes for the printing of this honeycomb are selected considering the compression and energy absorption properties simultaneously. The novel honeycomb is designed and printed with fused deposition modeling technology, which have hexagonal configuration (Structure I) and semi-triangular configuration (Structure II) under external temperature stimulus. The energy absorption capacity of Structure I and compressive properties of Structure II are investigated under different manufacturing process parameters. The experimental results indicate that the layer thickness has the most significant impact on the mechanical performance of deformable honeycombs. The combination of a layer thickness of 0.2 mm, printing speed of 40 mm s−1, and 100% infill density are the best process parameters for the novel deformable honeycomb structures.

Conceptual Design and Materials Selection of the FDM Composites for Passenger Vehicle’s Spoiler

One of the additive manufacturing techniques available is Fused Deposition Modeling (FDM), which offers advantages in design flexibility, cost-effectiveness, and the ability to produce intricate designs. Therefore, FDM for the 3D-printed vehicle’s car spoiler is a subject that can be explored. The FDM technology can significantly reduce time and cost before mass production, and the vehicle’s car spoiler was used as the case study in this research. The research investigates the mechanical properties of various commercial PLA composite filaments, addressing the lack of specifications provided by manufacturers. Testing four types of filaments—PLA/bamboo, PLA/coconut, PLA/wood, and PLA/metal. This research also emphasizes the conceptual design generation and selection for the passenger vehicle’s spoiler. Five design concepts were generated using the morphological chart for the passenger vehicle’s spoiler. The Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) method was used as the decision-making tool. As a result, PLA/metal, with 53.65 MPa and 70.23 MPa, showed the highest tensile and flexural strength values, respectively. Design concept 5 with the infill pattern of rib + I was the best from the finite element analysis (FEA) using SolidWorks simulation software. Finally, the TOPSIS technique revealed PLA/metal as the best PLA composite filament for car spoilers, scoring first in performance score with a value of 0.5774. This study demonstrates that by using a systematic approach, researchers may choose the best design concept and material choice by combining the conceptual design, experimental, simulation, and TOPSIS methods.

Environmental Assessment on Fabrication of Bio-composite Filament Fused Deposition Modeling Through Life Cycle Analysis

The environmental effect of a manufacturing or service method is determined by the resource and energy inputs and outputs at each point of the product’s life cycle. In Fused Deposition Modeling (FDM), generally, the material used for fabrication is plastic, and the raising of interest from different backgrounds of users could increase the issue of plastic pollution. Therefore, many scholars have proposed an initiative to employ bio-composite in FDM. In this study, an environmental assessment of global warming potential and fine particulate matter emission from the fabrication of bio-composite filament FDM was performed through its life cycle analysis using GaBi Software. Initially, data on resources and energy inputs and outputs were gathered. The functional unit in this study was the 1.0 kg wood/PLA composite filament extruded using a twin-screw extruder. All wastes were collected and recycled. The fabricated composite filaments were transported by container ship with a capacity of 5000 – 200 000 dwt gross weight for 100 km within Malaysia. Based on the results from the GaBi dashboard, the FDM process of bio-composite filament has contributed as much as 138.7 kg CO2 eq on the global warming potential and 1.71e-4 kg N eq. on fine particulate matter by the electricity power generation in extrusion and printing processes. The main factor for this issue is the consumption of coal in electric power generation, which is considered a non-renewable resource. Therefore, it is recommended that natural fibers such as wood fiber be employed in the filament of FDM to reduce the environmental impact. As shown in the study, the materials contribute less to the impact. Further study is suggested to compare the FDM technology with conventional technology using similar materials.

Reproducibility and air gap pockets of 3D-printed brachytherapy applicator placement in high-dose-rate skin cancer

Background and PurposeThis study aimed to investigate the reproducibility of a novel approach using 3D printed brachytherapy applicators for the treatment of skin cancer. Specifically, we aimed to assess the accuracy of applicator placement and to minimize the existence of air gap pockets between the applicator and the patient’s skin. Materials and MethodsA total of 20 patients plans diagnosed with skin cancer were enrolled in this study. All patients underwent high dose rate (HDR) brachytherapy. To ensure precise applicator placement, patient-specific 3D printed applicators were designed based on individual body and tumor topography, utilizing data obtained from computer tomography (CT) scans. All applicators were fabricated using fused deposition modeling technology. ResultsThe error in applicator placement was measured and found to be less than 1.0 mm on average, with a standard deviation of 0.9 mm. Additionally, the average error in air gap pockets between the applicator and the patient’s skin was 0.4 mm (standard deviation was 0.5 mm). The study demonstrated that the personalized approach of 3D printed brachytherapy applicator placement in skin cancer treatment yielded highly accurate results. The average error of less than 1.0 mm in applicator positioning and the minimal air gap pockets demonstrated the reproducibility and precision of this technique. ConclusionOur study establishes the reproducibility and accuracy of 3D-printed brachytherapy applicator placement in the treatment of skin cancer. This personalized treatment approach offers a highly precise method for delivering radiation therapy, minimizing the risk to adjacent healthy tissues, and enhancing overall patient outcomes.

A scientometrics study and its practical implications for fused deposition modeling

This study presents a scientometric analysis focusing on fused deposition modeling (FDM), highlighting key findings such as the top contributing nations, prevalent publication types, and prominent publishers. It tracks changes in FDM research over time, noting a significant increase in publications, and identifies popular keywords indicating recurring topics in the field. Additionally, the analysis explores highly cited journals and their burst rates, concluding with an examination of research categories and institutes involved in FDM research. These insights offer valuable guidance for researchers, institutions, and stakeholders interested in advancing FDM technology, with practical implications discussed. The detailed examination of the scholarly landscape in FDM contributes to a deeper understanding of the field's dynamics and potential avenues for future research and innovation.

Research of Layer Thickness and Selected Thermoplastic Materials and their Influence on the Surface Roughness in the Process of Fused Deposition Modeling Technology

This paper focuses on the influence of layer thickness and five selected thermoplastic materials on the surface roughness of cuboidal sample in the process of manufacturing by Fused Deposition Modelling technology. The component, in this case, is a cuboidal specimen with the dimensions 15 mm by 15 mm by 30 mm. FDM or LPD/FFF is additive layer-based method of additive manufacturing, usually used for rapid prototyping of the prototypes and other fabricating applications which use thermoplastics materials. A geometric model is defined that takes into account the shape of the fibers of the material after application to define the theoretical roughness profile. The authors set four different layer thicknesses of the cuboid part: 0.29 mm, 0.19mm, 0.14 mm and 0.09 mm. In this experiment, authors also used five different thermoplastic filaments: ABS, ASA, HIPS, PCABS and PLA. The authors produced a total of 20 prints and the surface of each sample was measured three times in succession using a portable surface roughness tester Mitutoyo. SJ-210. The 3D printer used in the experiment was Zortrax M200. The surface roughness .in this paper is shown in .the .form of a scatter and bar graph.

3D printed orthopedic prostheses for domestic and wild birds—case reports

Regardless of the species, birds are exposed to injuries that lead to amputation of part of the body structure and often euthanasia. Based on the need for new technologies that improve the quality of life of birds with locomotor problems, the present case reports aimed to describe the development of custom-made three-dimensional (3D) prostheses for domestic and wild birds that suffered amputation or malformation of the hind limb. Using the measurements of the bird, a digital model was created for 3D printing using fused deposition modeling technology (FDM) by the Brazilian company 3D Medicine. In this study we report the use of 3D prosthesis for the rehabilitation of three birds with locomotor disorders in Brazil, the animals adapted to the custom-made prosthesis with an improvement in quality of life, better distribution of body weight, locomotion, and landing. This study describes the development of 3D prostheses for birds in Brazil, the first report of this technology for these species, and the pioneering development of socket prostheses for small birds. 3D prostheses offer a high-efficiency solution to improve the quality of life of animals with amputations and malformations of the hind limbs. In addition, 3D technology provides valuable tools for veterinary medicine, developing custom-made models for the most different anatomical demands of animal patients.

Optimasi Variasi Jumlah Blade Inlet Turbo dan Outlet Turbo Terhadap Gaya Dorong Pada Prototype Waterjet Thrusther Produk 3D Printing Menggunakan Metode Taguchi

Efforts to improve Indonesia's maritime security continue to be increased by carrying out maritime security operations using a patrol fleet. The ability to maneuver well is needed by a ship to carry out encryption and security against enemies. This research aims to find a combination of Waterjet Thrusther ship propulsion system components that produces the most optimal thrust. The Waterjet Thrusther prototype was made using a 3D printing machine with FDM (Fused Deposition Modeling) technology using ST-PLA (Super Tough Polylactic Acid) filament. This research uses the Taguchi method to create an experimental design. The variables used are the number of turbo inlet blades, impeller type, and the number of turbo outlet blades. The test was carried out using tools in the form of a test vessel weighing 8.06 kg with an electric motor drive engine. The results of this test obtained the highest thrust force in the 2nd variation using a 3 blade type 2 impeller, 13 blade turbo inlet, and 13 blade turbo outlet with the lowest thrust force value of 2.231775 N. The 9th variation produced the lowest thrust force of 0,711225 N using Inlet Turbo 15 blades, Impeller 3 blade type 3, and Outlet Turbo 15 blades.

Effects of TPU on the mechanical properties, fracture toughness, morphology, and thermal analysis of 3D‐printed ABS‐TPU blends by FDM

AbstractIn this paper, blends of ABS‐TPU with two different weight percentages of TPU were prepared using fused deposition modeling technology. The effect of adding TPU on the fracture toughness of ABS and mechanical properties was comprehensively studied. Tensile, compression, fracture toughness, and shear tests were conducted on the 3D‐printed samples. Thermal and microstructural analyses were performed using dynamic mechanical thermal analysis (DMTA), and scanning electron microscope (SEM). The DMTA results showed that adding TPU decreased the storage modulus and the glass transition temperature of ABS, as well as its peak intensity. The mechanical test results showed that adding TPU decreased the strength but increased the formability and elongation of the samples. Fracture tests showed that the addition of TPU decreased the maximum force needed for a crack to initiate. The force required for crack initiation decreased from 568.4 N for neat ABS to 335.3 N for ABS80 and 123.2 N for ABS60. The ABS60 blend exhibited the highest strength against crack growth, indicating that TPU can change the behavior of ABS from brittle to ductile. Shear test results and SEM images also showed good adhesion strength between the printed samples for all three specimens, indicating their good printability. Adding TPU resulted in a reduction in the size and number of voids and holes between the printed layers.Highlights Melt mixing, filament preparation, and 3D printing of ABS‐TPU blends. Investigation of mechanical properties, microstructure, and fracture toughness. Improved resistance to crack growth and elongation by adding TPU to ABS. Improving printability and reducing microholes in blends compared with ABS. Achieving a wide range of mechanical properties for various applications.