Optimization of infill density, fiber angle, carbon fiber layer position in 3D printed continuous carbon-fiber reinforced nylon composite

Composite materials have gained much attention in various industries, such as aerospace, automotive, sports, marine, and construction, as these sectors rely on high-performance, durable, and cost-effective materials. Such materials offer high strength, stiffness and heat resistance. However, the influence of printing parameters especially the position of carbon fiber layer on such material is rarely found in literature. The current study focuses on optimizing different printing and testing parameters such as carbon fiber layer position, infill density, fiber angle, and strain rate in 3D printed carbon-fiber reinforced nylon composite. The study also recommended the optimal combination of these parameters for maximizing the mechanical strength and energy absorption of related 3D printed parts. The investigation revealed that the most optimum condition was 80% infill density, fiber angle of 0°, carbon fiber layer position of 12–13, and strain rate of 10 mm/min. It has been found in the study that fiber angle was the most dominant input parameter with a contribution of 54.13%, whereas infill density was the second dominant parameter with a contribution of 16.25%. The study also found that the position of the carbon fiber layer has comparatively less effect on the final mechanical properties of 3D printed parts, with a contribution of 10.12%. To facilitate the optimization, the outcomes will be helpful for designing and manufacturing 3D printed carbon-fiber reinforced nylon composite parts.