Analysis and Optimization of Mechanical Properties of Coconut Fiber-Reinforced Polymer Composite Fabricated Using Fused Filament Fabrication

Abstract

Due to the increasing global campaign to minimize greenhouse gas emissions and the need for sustainability in manufacturing, research is being focused on renewable and environmentally friendly materials to substitute synthetic and petroleum-based products. Natural fiber-reinforced polymeric composites are being investigated as potential substitutes for synthetic materials. In this research study, the suitability of coconut fiber-reinforced polypropylene as a structural material has been explored. By investigating these composites, the research contributes to the global shift toward environmentally friendly and renewable alternatives to synthetic materials. Samples of coconut fiber-reinforced polypropylene composites were prepared using fused filament fabrication and the tensile properties, flexural stiffness, and compression properties were tested for different proportions of coconut fiber and fused filament fabrication print speed factors. Analysis of variance was used to determine the critical factors that influence a specific output parameter. It was established that both the proportions of coconut fiber and print speed affect the mechanical properties of the polymeric composite, with the proportion of coconut fiber having the highest impact on the mechanical properties of the composite. Grey Relational Analysis was employed to determine the optimum input variables that produce the best enhanced mechanical properties. The optimum input parameters for maximized mechanical properties were found to be a fiber loading of 2wt% and a print speed factor of 100%. The optimized input parameters produced a tensile strength of 34.1 MPa, a Compression strength of 70.5 MPa, a flexural strength of 33.9 MPa, and flexural modulus of 4.7 GPa. Compared to pure polypropylene, the tensile strength and compression strength were increased by 52.9% and 19.4%, respectively. The flexural strength and flexural modulus were increased by 90.5% and 123.8%, respectively. The overall standard deviation for the measurement of mechanical properties was 6.9%. The composite produced has the potential to be applied in automobile vehicle parts such as bumper fascia, dashboards, and door panels. xvi