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Highlights:Graphical/Tabular Abstract  Composite filament manufacturing for use in FDM 3D printer  Effect of short carbon fiber ratio on mechanical properties  Effect of short carbon fiber ratio on porosity and melt flow indexThe paper investigates feasibity of FDM 3D printing of 6 mm long carbon fibre reinforced acrylonitrilebutadiene-styrene (ABS) composite filaments. The 3D printed part strength has been significantly improved with 6 mm long carbon fibre reinforcement with the flexibility and processability of the fibres is diminishing with increasing reinforcement content. It has also been determined that the print pattern significantly affects the mechanical properties. Figure A. Composite filament preparation and 3D printingPurpose: Filaments produced with the addition of 6 mm long fibres in ABS matrix in this work aims to improve mechanical properties of the FDM printed parts to enable widespread application of this most popular and inexpensive 3D printing method in direct manufacturing of final, ready for use parts. Theory and Methods:The 6 mm long carbon fibers has been dispersed in ABS granules using a doublescrew extruder with a backflow facility. The mixture has been further processed in a single-screw extruder to produce standard filaments suitable for commercial 3D printers. The carbon fibre re-inforced filament with various wt% CF-ABS has been used in a commercial 3D printer to produce ASTM D412 A standard tensile test models. Results:Tensile test results clearly suggested that specimens with higher wt% carbon fibre ratio are stronger than specimens with lower and that raster orientation has a significant effect on the mechanical properties of material. On the other hand toughness and ductility decreases with increasing carbon fibre content.Conclusion: Extrusion temperature and speed play an important role in filament quality which subsequently affects 3D printed part quality. Physical fracture of the fibers in high wt% carbon fibre loading gives rise to porosity in the parts and hence reduces tensile strength. Fiber length, porosity and matrix-fiber interface has also been shown to significantly affect the fluidity behavior of the composite material.

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