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Оbjectives: to establish a process window for pilot-scale twin-screw compounding of polyethylene terephthalate glycol (PETG) with short carbon fibre for subsequent FFF filament production and to identify the parameters that are critical to material reproducibility.
Methods. Two formulations containing 5 and 10 wt% carbon fibre and 2 wt% maleic-anhydride-functionalised low-density polyethylene were analysed. PETG was dried at 65 °C for 3 h, milled to 50–150 μm and sieved. Compounding was performed in a 30 mm twin-screw extruder with L/D = 44 at 220 rpm, a melt pressure of 1.0 MPa and a drive load of 70%. Descriptive analysis included screw length, peripheral speed, component mass ratios and the 11-zone thermal profile.
Results. The thermal sequence comprised heating from 200 to 240 °C with a 240 °C plateau, controlled cooling to 210 °C, and terminal stabilisation at 230 °C. The active screw length was 1.32 m and the peripheral speed was 0.346 m/s. For 5 and 10 wt% fibre, PETG-to-fibre ratios were 18.6 and 8.8, while compatibiliser-to-fibre ratios were 0.40 and 0.20. A critical-parameter map covering initial polymer drying through final pellet drying was developed. Pilot-batch filament was processable on an open-frame FFF printer; the screening flexural modulus was 3.5–4.0 GPa.
Conclusions. Reproducible carbon-filled PETG requires coordinated control of moisture, feeding, thermomechanical history and strand drawing. The 3.5–4.0 GPa value is flexural modulus, not flexural strength. Separating fibre-content and supplier effects requires factorial experiments, rheology, microscopy and standardised mechanical testing.
Methods. Two formulations containing 5 and 10 wt% carbon fibre and 2 wt% maleic-anhydride-functionalised low-density polyethylene were analysed. PETG was dried at 65 °C for 3 h, milled to 50–150 μm and sieved. Compounding was performed in a 30 mm twin-screw extruder with L/D = 44 at 220 rpm, a melt pressure of 1.0 MPa and a drive load of 70%. Descriptive analysis included screw length, peripheral speed, component mass ratios and the 11-zone thermal profile.
Results. The thermal sequence comprised heating from 200 to 240 °C with a 240 °C plateau, controlled cooling to 210 °C, and terminal stabilisation at 230 °C. The active screw length was 1.32 m and the peripheral speed was 0.346 m/s. For 5 and 10 wt% fibre, PETG-to-fibre ratios were 18.6 and 8.8, while compatibiliser-to-fibre ratios were 0.40 and 0.20. A critical-parameter map covering initial polymer drying through final pellet drying was developed. Pilot-batch filament was processable on an open-frame FFF printer; the screening flexural modulus was 3.5–4.0 GPa.
Conclusions. Reproducible carbon-filled PETG requires coordinated control of moisture, feeding, thermomechanical history and strand drawing. The 3.5–4.0 GPa value is flexural modulus, not flexural strength. Separating fibre-content and supplier effects requires factorial experiments, rheology, microscopy and standardised mechanical testing.
1. Petrov P.A., Agzamova D.R., Shmakova N.S. et al. Properties of PETG plastic after 3D printing using FFF technology. Part 1. Machine tools. 2022. No. 1 (26). P. 52 – 59. DOI: 10.22184/2499-9407.2022.26.1.52.59
2. Petrov P.A., Agzamova D.R., Shmakova N.S. etc. Properties of PETG plastic after 3D printing using FFF technology. Part 2. Machine tools. 2022. No. 2 (27). P. 58 – 64. DOI: 10.22184/2499-9407.2022.27.2.58.64
3. Valvez S., Silva A.P., Reis P.N.B. Optimization of printing parameters to maximize the mechanical properties of 3D-printed PETG-based parts. Polymers. 2022. Vol. 14.No. 13. Art. 2564. DOI: 10.3390/polym14132564
4. Fiorillo C., Ohnmacht H., Reyes P. et al. Quantifying hydrolytic degradation of poly(ethylene tereph-thalate glycol) under storage conditions and for fused filament fabrication mechanical properties. Polymer Degradation and Stability. 2023. Vol. 217. Art. 110511. DOI: 10.1016/j.polymdegradstab.2023.110511
5. Wang C., Huang H., Wang X., Wang Y., Zhu Y. Effect of drying treatment on the physical and mechanical properties of material extrusion-based 3D-printed PETG models. BioResources. 2025. Vol. 20. No. 3. P. 7000 – 7009. DOI: 10.15376/biores.20.3.7000-7009
6. García E., Núñez P.J., Caminero M.A., Chacón J.M., Kamarthi S. Effects of carbon fiber reinforcement on geometric properties of PETG-based filament using FFF additive manufacturing. Composites Part B: Engineering. 2022. Vol. 235. Art. 109766. DOI: 10.1016/j.compositesb.2022.109766
7. Mahesh V., Joseph A. S., Mahesh V. et al. Investigation on the mechanical properties of additively manufactured PETG composites reinforced with OMMT nanoclay and carbon fibers. Polymer Composites. 2021. Vol. 42. No. 5. P. 2380 – 2395. DOI: 10.1002/pc.25985
8. Kichloo A.F., Raina A., Haq M. I. ., Wani M.S. Impact of carbon fiber reinforcement on mechanical and tribological behavior of 3D-printed polyethylene terephthalate glycol polymer composites–an exper-imental investigation. Journal of Materials Engineering and Performance. 2022. Vol. 31. No. 2. P. 1021 – 1038. DOI: 10.1007/s11665-021-06262-6
9. Alarifi I.M. PETG/carbon fiber composites with different structures produced by 3D printing. Polymer Testing. 2023. Vol. 120. Art. 107949. DOI: 10.1016/j.polymertesting.2023.107949
10. Batista M., Lagomazzini J.M., Rodríguez-Parada M., Vazquez-Martinez J.M. Mechanical and tribological performance of carbon fiber-reinforced PETG for FFF applications. Applied Sciences. 2023. Vol. 13. No. 23. Art. 12701. DOI: 10.3390/app132312701
11. Janković M., Balać I., Popović M., Pjević M., Miloš M. Tensile strength and stiffness properties of additively manufactured PET-G polymer-based composite plates reinforced with different weight fractions of short carbon fibers. Journal of Mechanical Science and Technology. 2024. Vol. 38. No. 6. P. 2971 – 2977. DOI: 10.1007/s12206-024-0517-y
12. Economides A.L., Islam M.N., Baxevanakis K.P. Additively manufactured carbon fiber PETG composites: effect of print parameters on mechanical properties. Polymers. 2024. Vol. 16. No. 23. Art. 3336. DOI: 10.3390/polym16233336
13. Hwang S.W., Ryu H.C., Kim S.W., Park H.Y., Seo K.H. Grafting maleic anhydride onto EVA and effect on the physical and rheological properties of PETG/EVA-g-MAH blends. Journal of Applied Polymer Science. 2012. Vol. 125. No. 4. P. 2732 – 2739. DOI: 10.1002/app.36592
2. Petrov P.A., Agzamova D.R., Shmakova N.S. etc. Properties of PETG plastic after 3D printing using FFF technology. Part 2. Machine tools. 2022. No. 2 (27). P. 58 – 64. DOI: 10.22184/2499-9407.2022.27.2.58.64
3. Valvez S., Silva A.P., Reis P.N.B. Optimization of printing parameters to maximize the mechanical properties of 3D-printed PETG-based parts. Polymers. 2022. Vol. 14.No. 13. Art. 2564. DOI: 10.3390/polym14132564
4. Fiorillo C., Ohnmacht H., Reyes P. et al. Quantifying hydrolytic degradation of poly(ethylene tereph-thalate glycol) under storage conditions and for fused filament fabrication mechanical properties. Polymer Degradation and Stability. 2023. Vol. 217. Art. 110511. DOI: 10.1016/j.polymdegradstab.2023.110511
5. Wang C., Huang H., Wang X., Wang Y., Zhu Y. Effect of drying treatment on the physical and mechanical properties of material extrusion-based 3D-printed PETG models. BioResources. 2025. Vol. 20. No. 3. P. 7000 – 7009. DOI: 10.15376/biores.20.3.7000-7009
6. García E., Núñez P.J., Caminero M.A., Chacón J.M., Kamarthi S. Effects of carbon fiber reinforcement on geometric properties of PETG-based filament using FFF additive manufacturing. Composites Part B: Engineering. 2022. Vol. 235. Art. 109766. DOI: 10.1016/j.compositesb.2022.109766
7. Mahesh V., Joseph A. S., Mahesh V. et al. Investigation on the mechanical properties of additively manufactured PETG composites reinforced with OMMT nanoclay and carbon fibers. Polymer Composites. 2021. Vol. 42. No. 5. P. 2380 – 2395. DOI: 10.1002/pc.25985
8. Kichloo A.F., Raina A., Haq M. I. ., Wani M.S. Impact of carbon fiber reinforcement on mechanical and tribological behavior of 3D-printed polyethylene terephthalate glycol polymer composites–an exper-imental investigation. Journal of Materials Engineering and Performance. 2022. Vol. 31. No. 2. P. 1021 – 1038. DOI: 10.1007/s11665-021-06262-6
9. Alarifi I.M. PETG/carbon fiber composites with different structures produced by 3D printing. Polymer Testing. 2023. Vol. 120. Art. 107949. DOI: 10.1016/j.polymertesting.2023.107949
10. Batista M., Lagomazzini J.M., Rodríguez-Parada M., Vazquez-Martinez J.M. Mechanical and tribological performance of carbon fiber-reinforced PETG for FFF applications. Applied Sciences. 2023. Vol. 13. No. 23. Art. 12701. DOI: 10.3390/app132312701
11. Janković M., Balać I., Popović M., Pjević M., Miloš M. Tensile strength and stiffness properties of additively manufactured PET-G polymer-based composite plates reinforced with different weight fractions of short carbon fibers. Journal of Mechanical Science and Technology. 2024. Vol. 38. No. 6. P. 2971 – 2977. DOI: 10.1007/s12206-024-0517-y
12. Economides A.L., Islam M.N., Baxevanakis K.P. Additively manufactured carbon fiber PETG composites: effect of print parameters on mechanical properties. Polymers. 2024. Vol. 16. No. 23. Art. 3336. DOI: 10.3390/polym16233336
13. Hwang S.W., Ryu H.C., Kim S.W., Park H.Y., Seo K.H. Grafting maleic anhydride onto EVA and effect on the physical and rheological properties of PETG/EVA-g-MAH blends. Journal of Applied Polymer Science. 2012. Vol. 125. No. 4. P. 2732 – 2739. DOI: 10.1002/app.36592
Ilyukhin D.A. Process window for twin-screw compounding of PETG with short carbon fibre for FFF filament. Chemical Bulletin. 2026. 9 (2). 5. https://doi.org/10.58224/2619-0575-2026-9-2-5