Evaluation of 3D-Printed ABS-Based honeycomb biocomposites reinforced with sugarcane bagasse biosilica under friction stir welding: mechanical, wear, and flammability behavior

The target of this research was to develop Acrylonitrile Butadiene Styrene (ABS) filaments reinforced with varying volume percentages of biosilica particles for use in 3D printing applications. ABS filaments and 3D-printed samples were fabricated according to ASTM standards, and their mechanical, thermal, and tribological behavior was evaluated through tensile, flexural, impact, hardness, flammability, and wear tests. Among all the samples, the 3D-printed sample B3 containing 5 vol.% biosilica exhibited the highest tensile strength (144 MPa), flexural strength (128 MPa), and impact strength (2.04 J), while the neat ABS sample (B) showed the lowest strength due to the absence of reinforcement. The developed composites demonstrated improved stiffness, impact resistance, and functional performance suitable for structural applications. Additionally, the B1 sample displayed excellent wear resistance, with a specific wear rate of 0.049 mm3/Nm and a coefficient of friction of 0.62. SEM analysis confirmed uniform filler distribution and acceptable surface morphology of the 3D-printed composites. Key applications for these ABS/biosilica composites include lightweight functional components in automotive interiors, consumer electronics housings, protective casings for equipment, customized tooling, and structural parts requiring enhanced stiffness, impact resistance, and wear durability.