Evaluating the Durability of Anti-Lock Braking Systems (ABS) and Carbon Fiber Nylon Components
In a recent experiment, a YouTube channel named Functional Print Friday demonstrated the significant improvements in strength and durability that can be achieved when printing car replacement parts at a 45° angle and incorporating machine screws into the design.
The experiment compared the performance of a new replacement part, printed in carbon fiber-reinforced nylon (PAHT-CF, or PA12), with the original part, which was printed in ABS filament and printed horizontally. The new part was strategically reinforced with machine screws, particularly in the critical stop element, which proved to be highly effective.
The 45° print angle was found to enhance the part's resistance to failure. By changing the orientation of the layer lines, stress is distributed more evenly along the layers, reducing the likelihood of layers snapping, as was the case with the original horizontal ABS print. This optimised print orientation, combined with mechanical reinforcement from machine screws, significantly increased the load the part could withstand.
The machine screw-reinforced stop, in combination with the PA12 CF filament, proved to be particularly effective in improving the durability of the angled parts. In destructive testing, the angled parts demonstrated better resistance to failure compared to the original horizontal ABS print, with the machine screw-reinforced stop significantly delaying failure of the angled parts.
The use of carbon fiber-reinforced nylon filament also contributed to the increased durability of the angled parts. In fact, the machine screw-reinforced stop combined with the PA12 CF filament maxed out the first meter in load tests, showing superior performance compared to the horizontally printed ABS part without screw reinforcement.
The FDM 3D printing process offers a variety of filament types and parameters, and changes in these parameters can sometimes have an impact that is hard to determine. However, the Functional Print Friday experiment clearly demonstrated that a combination of a 45° print angle and machine screws can yield replacement parts that are much stronger, longer-lasting, and more reliable for automotive use, even when printed on typical FDM 3D printers.
[1] Functional Print Friday (2021). 45 Degree Angled Parts with Machine Screws. [YouTube video]. YouTube. https://www.youtube.com/watch?v=7d_75KaKUlk
[2] Functional Print Friday (2021). Car Parts Load Test - 45 Degree Angled Parts with Machine Screws. [YouTube video]. YouTube. https://www.youtube.com/watch?v=IwZL_Q1-q0Q
[3] Functional Print Friday (2021). Car Parts Load Test - PAHT-CF (PA12) with Machine Screws. [YouTube video]. YouTube. https://www.youtube.com/watch?v=KgwJ1fVZqOY
- The functional experiment conducted by Functional Print Friday demonstrated that incorporating technology such as 45° printing and machine screws can result in car replacement parts with enhanced strength and durability.
- The use of machine screws, in combination with carbon fiber-reinforced nylon filament, considerably improved the durability of the angled printed parts, as shown in the YouTube videos by Functional Print Friday.
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