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Investigating Process-Structure-Property Relationships in Large-Scale Additively Manufactured Carbon-Filled PETg.

Christopher Bock1,2, Brett Ellis3, Masoud Rais-Rohani2

  • 1Advanced Structures and Composites Center, University of Maine, 35 Flagstaff Road, Orono, ME 04469, USA.

Materials (Basel, Switzerland)
|June 12, 2026
PubMed
Summary
This summary is machine-generated.

This study links additive manufacturing processes to the properties of carbon-fiber-reinforced PETg. Screw speed significantly influences fiber orientation, which in turn affects the material's stiffness and strength.

Keywords:
additive manufacturingextrusion-based additive manufacturingmechanical propertiesmicrostructurethermoplastic composites

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Additive manufacturing (AM) enables complex material fabrication but results in properties highly dependent on processing parameters.
  • Understanding the process-structure-property relationship is crucial for optimizing AM materials.

Purpose of the Study:

  • To experimentally investigate the process-structure-property linkage in carbon-fiber-reinforced PETg fabricated via large-scale additive manufacturing.
  • To establish a comprehensive dataset for validating predictive models.

Main Methods:

  • An experimental design with eight parameter combinations (layer height, feed rate, bead spacing, screw speed) was employed.
  • Microstructure analysis (fiber orientation, porosity) and flexural testing (strength, stiffness) were performed on numerous specimens.
  • High-speed photography and fractography were used to analyze fracture behavior.

Main Results:

  • In-plane modulus ranged from 13.3–18.6 GPa; strength ranged from 158–189 MPa.
  • Inter-layer stiffness ranged from 2.9–3.2 GPa; strength ranged from 31.4–45.0 MPa.
  • Screw speed strongly correlated with fiber orientation, which directly impacted stiffness and strength.

Conclusions:

  • A significant process-structure-property relationship was identified for carbon-fiber-reinforced PETg.
  • The generated dataset serves as a valuable reference for AM process and material modeling.
  • Screw speed is a critical parameter for controlling mechanical performance through fiber orientation.