Studying the effect of carbon black and printing parameters on the mechanical properties of POE-CB composite using the Taguchi method

Additive manufacturing of polymer composites holds significant potential for customizing mechanical performance, though optimizing process parameters poses a challenge. This study examines the impact of carbon black (CB) concentration (2.5–7.5 wt%), printing temperature (190–220 °C), and printing velocity (200–400 mm/s) on the mechanical properties of 3D-printed polyolefin elastomer (POE)-CB composites, employing a Taguchi L9 orthogonal array design. Signal-to-noise (S/N) ratio analysis determined optimal settings: A2B3C2 (5 wt% CB, 220 °C, 300 mm/s, where A = CB concentration, B = temperature, C = velocity) for ultimate tensile strength (UTS), and A3B3C2 (7.5 wt% CB, 220 °C, 300 mm/s) for elongation at break (El) and modulus of toughness, with peak performance in Run 9 (UTS: 6.81 MPa, El: 2274.09%, modulus of toughness: 12.04 J/m³). Analysis of variance (ANOVA) highlighted the CB concentration × printing temperature interaction’s notable contribution (UTS: 24.93%, El: 15.37%, modulus of toughness: 18.77%), with regression equations indicating trends of enhanced effects at higher levels, though statistical significance remains unestablished. SEM analysis correlated these mechanical gains with improved CB dispersion and interlayer bonding at elevated CB content and temperature, while moderate velocity reduced defects. This study offers a promising approach for optimizing 3D-printed polymer composites, supporting applications in soft robotics and wearable devices, and suggests future research to strengthen statistical power and investigate advanced filler techniques.