Eco-friendly ABS composites with pistachio shell powder reinforcement: mechanical and microstructural evaluation

Abstract Acrylonitrile Butadiene-Styrene (ABS) composites are being used for various engineering applications due to their higher toughness, strength, and lightweight. The properties of ABS reinforced with pistachio shell powder (PSP) have been investigated. PSP was incorporated into the ABS matrix at varying weight fractions (0%, 1%, 3%, and 5%), and composite filaments were fabricated via single screw extrusion. The experiments are conducted as per the Taguchi L16 method to analyse parameters: layer thickness (LT), infill density (ID), nozzle temperature (NT), PSP content, and infill pattern (IP) on mechanical properties. Standardized testing, in accordance with American Society for Testing and Materials (ASTM) D638, D790, D695, and D256, was conducted to evaluate tensile, flexural, compressive, and impact behaviour. The results revealed that a 3% PSP composition, coupled with an LT 0.4 mm, and ID 65–80%, yielded optimal tensile and flexural performance. The maximum tensile strength is found to be 33 MPa and modulus of 457 MPa, while the highest compressive strength reached 71 MPa at 5% PSP. Analysis of variance (ANOVA) identified PSP composition and infill density as the most significant contributors to mechanical enhancement. The findings confirm the viability of PSP as a sustainable, cost-effective reinforcement for ABS in FDM-based applications, with promising implications for eco-friendly composite manufacturing.