Title: Hybrid Composites via Co-Extrusion Additive Manufacturing-Compression Molding for Performance Optimization

Authors: Sanjita Wasti, Segun Isaac Talabi, Amber Hubbard, Adwoa Owusu, Vipin Kumar, Halil Tekinalp, Chinmay Mungale, Uday Vaidya, Ahmed Hassen, Soydan Ozcan

DOI:

Abstract: The growing demand for hybrid polymer composites with multifunctional properties has led to the development of various hybridization techniques, such as multi-material compounding and controlled laminate stacking sequence. In this study, a novel hybrid manufacturing approach was used by integrating a multiplexing extrusion system (MExS) based on additive manufacturing with subsequent compression molding process. This technique enabled the co-extrusion of different materials during the additive manufacturing process to fabricate composites with tailored performance. The developed hybrid composite featured a skin layer of glass fiberreinforced polycarbonate (PC/GF) encapsulating a carbon fiber-reinforced acrylonitrile butadiene styrene (CF/ABS) core. The structure was engineered to promote improved thermal and impact resistance at the surface, supported by a stiff core for enhanced overall mechanical integrity. Mechanical, thermal and morphological properties of the hybrid composites were investigated to understand trade-offs in performance compared to a single-material system. The results demonstrate that this approach enables the production of multifunctional composites suitable for applications such as automotive body panels and protective housings, where a balance of weight, mechanical strength, and thermal performance is essential.

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Conference: SAMPE 2026

Publication Date: 2026/04/27

SKU: 77

Pages: 13

Price: $26.00