On fabrication of acrylonitrile butadiene styrene-zirconium oxide composite feedstock for 3D printing-based rapid tooling applications

The 3D-printed rapid tools are being used in finishing operations such as drilling, milling, broaching, roller burnishing, and other finishing operations that need anti-wear plastic composite materials. Zirconium oxide (ZrO2) is one of the ceramic materials which is highly appreciated due to its anti-wear properties. This study aims to develop the ZrO2 ceramic particles reinforced acrylonitrile butadiene styrene (ABS) thermoplastic composite feedstock filaments for 3D printing of rapid tools. In the first stage, the multiple numbers (as per Taguchi L9 orthogonal array (OA)) of ABS-ZrO2 feedstock filaments were developed by varying the loading of ZrO2 in ABS matrix (2 wt.%, 4 wt.%, and 6 wt.%), processing temperature (200, 205 and 210°C), and rotation speed of screw (4, 6 and 8 RPM). The optimum setting obtained for manufacturing ABS-ZrO2 composite feedstock filaments is the combination of 2% ZrO2 loading, 205°C processing temperature, and 6 RPM screw speed. In the next stage, fused filament fabrication (FFF) based 3D printing has been used to prepare the rapid tools. The wear test performed for 3D printed ABS-ZrO2 composites rapid tools shows only .62% weight loss which is lower as compared to virgin ABS (.91% weight loss). The results of the study are supported by fracture analysis, morphology, and mechanical properties.