The present research work highlights the fabrication of Fe-nylon6 composite wire by varying proportion of Fe in nylon6 matrix (by weight) along with wear and friction characteristics of the composite wire. The composite wire prepared has been used as a feedstock filament in place of the existing ABS material in the fused deposition modelling (FDM) machine (without any software and hardware modifications in the existing FDM setup). Comparison of wear of three different Fe-nylon6 compositions and ABS at varying loads along with the variation of coefficient of friction and the frictional force has been carried out. The objective is to study the variation of wear and friction characteristics with the variation of the filler material (Fe) in the composite. It is concluded that all the three composite materials are highly wear resistant, having less friction coefficient, less frictional force than the recommended material (ABS) for FDM system. The surface morphology shows even distribution of Fe particles in the matrix which increases with the increase in percentage of Fe in the composite.