Design and performance of 3D-Printed ABS@rGO/CF/CeO₂ composites for microwave absorption and mechanical strength

Traditional microwave absorbing materials struggle to balance wideband absorption with mechanical properties, particularly in multifunctional applications. This study explores the effects of short carbon fibers (CF), cerium dioxide (CeO₂), and reduced graphene oxide (rGO) on the electromagnetic and mechanical properties of 3D-printed composites. The ABS@CF/CeO₂/rGO composite with a thickness of 2.2 mm exhibited exceptional microwave absorption, achieving an effective absorption bandwidth (EAB) of 6.6 GHz and a minimum reflection loss (RL_min) of −40.9 dB. The Whale Optimization Algorithm (WOA) was employed to design a load-bearing, microwave-absorbing superstructure, which significantly improved wideband absorption. Experimental results confirmed the superstructure's isotropy and wide-angle absorption capabilities. The calculated electromagnetic parameters were applied to evaluate the radar cross-section (RCS) of large targets, demonstrating enhanced stealth performance for unmanned aerial vehicles (UAVs). Mechanical tests revealed that rGO improved interlayer bonding strength, while CF negatively impacted bending performance. The superstructure also showed excellent mechanical stability in load-bearing tests, underscoring its potential for practical engineering applications. This study offers insights into designing advanced composite materials with balanced electromagnetic and mechanical properties, guiding future multifunctional material development.