Interfacial adhesion and failure transition governed by fibre embedded length in 3D-printed continuous carbon fibre–reinforced PETG composites.

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Title: Interfacial adhesion and failure transition governed by fibre embedded length in 3D-printed continuous carbon fibre–reinforced PETG composites.
Authors: Kumar, S. Siddharth1 (AUTHOR), Htike, Min H.1 (AUTHOR), Partanen, Jouni1 (AUTHOR), Almeida Jr, José Humberto S.2 (AUTHOR) humberto.almeida@lut.fi
Source: Journal of Thermoplastic Composite Materials. Jul2026, Vol. 39 Issue 7, p3660-3685. 26p.
Subjects: Fiber-matrix interfaces, Carbon fibers, Fibrous composites, Composite materials, Fiber testing, Shear strength, Mechanical behavior of materials
Abstract: The mechanical performance of additively manufactured composites is strongly governed by fibre–matrix interfacial adhesion, which can be compromised by process-induced imperfections. This study examines how fibre embedded length controls interfacial adhesion behaviour and failure mechanisms in 3D-printed continuous carbon fibre-reinforced polyethylene terephthalate glycol (PETG) composites, using single-fibre pull-out testing combined with scanning electron microscopy (SEM). Specimens with embedded lengths ranging from 1 mm to 50 mm were tested to capture the transition between fibre slippage and fibre fracture. A critical embedded length (L c ) of 4.88 ± 0.54 mm was determined, beyond which fibre fracture dominates. The apparent interfacial shear strength (IFSS) was measured as 18.6 ± 1.2 MPa, while the interfacial fracture energy (G c ) was calculated as 27.3 J/m2. A linear traction–separation cohesive law was fitted based on these experimental parameters. SEM imaging reveals distinct microstructural features associated with the two failure modes. These findings establish practical benchmarks for optimising fibre placement, orientation strategies, and load transfer efficiency in 3D-printed composites. The outcomes contribute to the advancement of lightweight composite structures for aerospace and automotive applications. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Thermoplastic Composite Materials is the property of Sage Publications Inc. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Interfacial adhesion and failure transition governed by fibre embedded length in 3D-printed continuous carbon fibre–reinforced PETG composites.
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Thermoplastic+Composite+Materials%22">Journal of Thermoplastic Composite Materials</searchLink>. Jul2026, Vol. 39 Issue 7, p3660-3685. 26p.
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  Data: <searchLink fieldCode="DE" term="%22Fiber-matrix+interfaces%22">Fiber-matrix interfaces</searchLink><br /><searchLink fieldCode="DE" term="%22Carbon+fibers%22">Carbon fibers</searchLink><br /><searchLink fieldCode="DE" term="%22Fibrous+composites%22">Fibrous composites</searchLink><br /><searchLink fieldCode="DE" term="%22Composite+materials%22">Composite materials</searchLink><br /><searchLink fieldCode="DE" term="%22Fiber+testing%22">Fiber testing</searchLink><br /><searchLink fieldCode="DE" term="%22Shear+strength%22">Shear strength</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink>
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  Data: The mechanical performance of additively manufactured composites is strongly governed by fibre–matrix interfacial adhesion, which can be compromised by process-induced imperfections. This study examines how fibre embedded length controls interfacial adhesion behaviour and failure mechanisms in 3D-printed continuous carbon fibre-reinforced polyethylene terephthalate glycol (PETG) composites, using single-fibre pull-out testing combined with scanning electron microscopy (SEM). Specimens with embedded lengths ranging from 1 mm to 50 mm were tested to capture the transition between fibre slippage and fibre fracture. A critical embedded length (L c ) of 4.88 ± 0.54 mm was determined, beyond which fibre fracture dominates. The apparent interfacial shear strength (IFSS) was measured as 18.6 ± 1.2 MPa, while the interfacial fracture energy (G c ) was calculated as 27.3 J/m2. A linear traction–separation cohesive law was fitted based on these experimental parameters. SEM imaging reveals distinct microstructural features associated with the two failure modes. These findings establish practical benchmarks for optimising fibre placement, orientation strategies, and load transfer efficiency in 3D-printed composites. The outcomes contribute to the advancement of lightweight composite structures for aerospace and automotive applications. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
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  Data: <i>Copyright of Journal of Thermoplastic Composite Materials is the property of Sage Publications Inc. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1177/08927057251408473
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      – Code: eng
        Text: English
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        PageCount: 26
        StartPage: 3660
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        Type: general
      – SubjectFull: Carbon fibers
        Type: general
      – SubjectFull: Fibrous composites
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      – SubjectFull: Composite materials
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      – SubjectFull: Fiber testing
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      – SubjectFull: Shear strength
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      – SubjectFull: Mechanical behavior of materials
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      – TitleFull: Interfacial adhesion and failure transition governed by fibre embedded length in 3D-printed continuous carbon fibre–reinforced PETG composites.
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            NameFull: Kumar, S. Siddharth
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            NameFull: Htike, Min H.
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            NameFull: Partanen, Jouni
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            NameFull: Almeida Jr, José Humberto S.
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            – D: 01
              M: 07
              Text: Jul2026
              Type: published
              Y: 2026
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