A review of dispersion mechanisms in graphene reinforced ABS nanocomposites for additive manufacturing

Abstract

Abstract Due to the enhanced mechanical, thermal, electrical, and tribological performance graphene-reinforced Acrylonitrile Butadiene Styrene (ABS) nanocomposites have emerged as promising materials for fused deposition modeling (FDM). However, realizing these improvements remains challenging because of graphene agglomeration and weak interfacial adhesion with the ABS matrix. This review significantly examines the impact of dispersion mechanisms and interfacial engineering on the performance of graphene–ABS nanocomposites. Different graphene derivatives, including graphene oxide (GO), reduced graphene oxide (rGO), and graphene nanoplatelets (GNPs), are compared with respect to their dispersion behavior, compatibility with ABS, and reinforcement efficiency. Processing techniques such as melt blending, solvent-assisted processing, and in-situ polymerization, together with functionalization strategies, are comprehensively reviewed. Reported studies indicate 25–45% improvement in tensile strength, 30–60% enhancement in fracture toughness, 20–50% increase in elastic modulus, 2–5 folds enhancement in thermal conductivity, 10–30 °C improvement in thermal stability, 30–70% reduction in wear rate and significant enhancement in electrical conductivity through percolation network formation with optimised graphene loading and processing. The review explores the relationships between structure, processing, and properties in grapheme–ABS nanocomposites. It highlights gaps in current research and offers practical design guidelines, along with future research directions, aimed at developing high-performance multifunctional materials for advanced additive manufacturing applications.