The spread of 3D printing in many different fields has become eminent. This paper aims to improve the mechanical properties of parts printed by fused deposition modeling technique. Acrylonitrile butadiene styrene (ABS) specimens are printed with custom printing parameters. These parameters give a tensile strength that is 86% of the injection- molded ABS strength, and give one of the best recorded results for 100% infill printed ABS tensile specimens. Furthermore, a post filling technique has been studied. Specimens are printed with inner voids and different densities using slicing software. Void shape is precisely selected to conform to the filling process. High-strength, low-cost thermoset resin is injected through specimens to fill those voids. A tensile test has been performed after the full curing of the resin. A morphology analysis is done. Using this technique strength to printed weight ratio is improved by 151% and the cost is reduced by 51%.

No one can deny the widespread of 3D printing in many different fields. This paper aims to improve the mechanical properties of parts printed by fused deposition modeling (FDM) technique. Acrylonitrile butadiene styrene (ABS) specimens are printed with custom printing parameters, these parameters give a tensile strength that is 86% of the injection molded ABS strength, and give one of the best results recorded for 100% infill printed ABS tensile specimens. Furthermore, a post filling technique has been studied, specimens are printed with inner voids and different densities using slicing software. Void shape is precisely selected to conform to the filling process. High-strength low-cost thermoset resin is injected through specimens to fill these voids. A tensile test has been performed after full curing of the resin and a morphology analysis is done. By this technique strength to printed weight ratio is improved by 151% and the cost is reduced by 51%.