Blend filaments of
acrylonitrile butadiene styrene (ABS) and thermoplastic
polyurethane (TPU) were prepared at different weight ratios, i.e.,
100:0, 70:30, 50:50, 30:70, and 0:100, for FDM printing; the prepared
filaments, with an average diameter of 2.77 ± 0.19 mm, were encoded
as A100, A70T30, A50T50, A30T70, and T100, respectively. The properties
and printability of the filaments were thoroughly investigated. The
blend composition, as well as the printing parameters, were optimized
to obtain the FDM-printed objects with a well-defined surface structure
and minimized warpages. The glass transition temperatures of ABS and
TPU in the blends were not much altered from those of the parent filaments,
whereas the thermal degradation characteristics of the blend filaments
still fell between those of the neat filaments. The fractured surfaces
of the filaments, observed by SEM, appeared smoother when higher amounts
of TPU integrated; the smoothest surface of the ABS-based filament
was found in A30T70, indicating the well-compatible blend characteristic.
This was also confirmed by its rheological behavior examined by a
parallel plate rheometer at 225 °C. Not only was the printability
of the filaments improved, but also the warpages of the 3D-printed
specimens were decreased when increasing amount of TPU was incorporated
into the filaments. Among the printed objects, the A30T70 specimen
exhibited the evenest surface morphology with the lowest surface roughness
value of 32.9 ± 13.2 nm and the most uniform and consistent linear
printing structure when being fabricated at the nozzle temperature
of 225 °C and the printing bed temperature of 60 °C. However,
the incorporation of TPU into the filaments markedly cut down both
strength and modulus values of the fabricated materials up to about
half but assisted the printed articles to absorb more energy, demonstrating
that this polymer served as a good and effective toughener for ABS.