Mechanical behaviour and structural performance of PLA+, ABS+, and e-ABS sandwich panels for additive manufacturing applications

Abstract The rapid evolution of 3D printing, also known as additive manufacturing, continues to transform various industries by enabling the fabrication of lightweight, complex, and customized structures. This study experimentally investigates the mechanical and thermal properties of 3D-printed sandwich panels using Polylactic Acid (PLA+), Acrylonitrile Butadiene Styrene (ABS+), and Enhanced Acrylonitrile Butadiene Styrene (e-ABS). Samples were prepared using FDM-based 3D printing with a honeycomb core structure and tested according to ASTM standards. Among the materials tested, PLA + demonstrated the highest compressive strength of 23.57 MPa, flexural strength of 39.63 MPa, and ultimate tensile strength (UTS) of 22.43 MPa, reflecting superior rigidity and load-bearing capacity. ABS + and e-ABS exhibited lower compressive strengths of 10.30 MPa and 10.07 MPa, and UTS values of 13.15 MPa and 12.33 MPa, respectively, with e-ABS offering slightly better flexibility due to a higher strain at break. Flexural modulus values also confirmed PLA + as the stiffest material at 3006.44 MPa, compared to 2093.84 MPa for ABS + and 1157.86 MPa for e-ABS. Thermal behaviour assessed via Differential Scanning Calorimetry (DSC) revealed glass transition temperatures of 66.95 °C (PLA+), 104.25 °C (ABS+), and 101.48 °C (e-ABS), indicating their suitability for varying thermal conditions. These results provide valuable insights into selecting appropriate 3D-printed thermoplastics for engineering applications requiring a balance of strength, stiffness, and thermal stability.