Additive Manufacturing of Polyphenylene Sulfide and their Carbon Compositions through Fused Filament Fabrication

This study explored the interlayer bonding strength enhancement through process parameters (print temperature chamber temperature and layer height) optimization of polyphenylene sulfide (PPS) parts printed with fused filament fabrication (FFF) by the response surface method (RSM). Using DSC, rheometer, and optical microscopy, it was revealed that interlayer bonding was significantly enhanced with parameters’ optimization showing tensile strength and Young’s modulus of 93% and 96% of compression molded specimen, respectively. Optimized parts showed excellent chemical resistance, suggesting potential for under-the-hood application.Moreover, recycled carbon fiber (rCF) reinforced PPS filaments with fiber percentages up to 10% were developed. The superior performance of parts containing 10% fiber (10%CF) was proved using mechanical (tensile, flexural, and impact) and thermal (DSC, TGA, and DMA) tests. Excellent chemical resistance and high print quality of an actual industrial part using 10%CF was verified. Mentioned results suggested a desirable performance of 10%CF for lightweight high-temperature applications in the automotive industry.M.A.S