Experimental analysis of 3D printed continuous carbon/glass hybrid fiber reinforced PLA composites: Revealing synergistic mechanical properties and failure mechanisms

Abstract This study investigates the mechanical properties of continuous carbon/glass hybrid fiber‐reinforced polylactic acid (PLA) composites (HFRC) produced through the three dimensions (3D) printing process, comparing them with single carbon fiber‐reinforced PLA composites (CFRC). Initially, composite prepreg filaments are prepared using an impregnation device, followed by fabrication using a 3D printer. The mechanical performance results reveal a 13% increase in tensile strength for HFRC compared with CFRC. Due to differing elongation rates of carbon and glass fibers, HFRC exhibits two strength peaks, while CFRC demonstrates a 37% higher bending strength than HFRC. Scanning electron microscope images indicate that the tensile failure mechanism involves fiber brittle fracture and fiber‐matrix interface debonding, while the bending failure mechanism includes fiber pullout, fiber debonding, fiber cluster buckling, and interlayer interface failure. Highlights To realize the moldless rapid manufacturing of continuous hybrid fiber‐reinforced PLA composites. The stress–strain curves of single fiber‐reinforced composites and hybrid fiber‐reinforced composites are obviously different. Elucidating the effect of single fiber/hybrid fiber in composites on mechanical properties and failure mechanism according to micro‐morphology.