Mechanical Characterization and Interface Evaluation of Multi-Material Composites Manufactured by Hybrid Fused Deposition Modeling (HFDM)

In this study, the mechanical behavior and interfacial bonding characteristics of multi-material composites produced using the Hybrid Fused Deposition Modeling (HFDM) technique were systematically investigated. Polylactic Acid (PLA), Polyethylene Terephthalate Glycol (PETG), and Acrylonitrile Butadiene Styrene (ABS) filaments were utilized within a single structure to explore the effects of material combinations on mechanical performance. Specimens were fabricated using two distinct levels of infill density (50-100%) and raster angle (45-90 degrees) to evaluate the influence of these parameters on tensile strength, flexural resistance, and impact toughness. Experimental tests were conducted following ASTM standards, and microstructural examinations were performed using Scanning Electron Microscopy (SEM) to assess interfacial adhesion between different polymers. The results revealed that PETG demonstrated the highest tensile strength among single-material samples, while the PLA-PETG-ABS configuration exhibited notable mechanical stability among hybrid structures. Increasing infill density and raster angle significantly enhanced mechanical performance across all configurations. SEM analyses confirmed that interfacial bonding quality critically affected structural integrity, with better adhesion observed in PLA-PETG interfaces compared to PLA-ABS transitions. The potential of HFDM in developing tailored multi-material components with optimized mechanical properties offers valuable insights for the advancement of functional additive manufacturing applications in engineering fields.