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Filament-based material extrusion (MEX) represents one of the most commonly used additive manufacturing techniques for polymer materials. In a special variation of this process, highly filled polymer filaments are used to create metal parts via a multi-step process. The challenges associated with creating a dense final part are versatile due to the different and partly contrary requirements of the individual processing steps. Especially for processing in MEX, the compound must show sufficiently low viscosity, which is often achieved by the addition of wax. However, wax addition also leads to a significant reduction in ductility. This can cause filaments to break, which leads to failure of the MEX process. Therefore, the present study investigates the influence of different ethylene-propylene copolymers (EPCs) with varying ethylene contents as a ductility-enhancing component within the feedstock to improve filament processing behavior. The resulting feedstock materials are evaluated regarding their mechanical, thermal and debinding behavior. In addition, the processability in MEX is assessed. This study shows that a rising ethylene content within the EPC leads to a higher ductility and an enhanced filament flexibility while also influencing the crystallization behavior of the feedstock. For the MEX process, an ethylene fraction of 12% within the EPC was found to be the optimum regarding processability for the highly filled filaments in MEX and the additional processing steps to create sintered metal parts., Competing Interests: The authors declare no conflicts of interest.

Agricultural waste is a renewable source of lignocellulosic components, which can be processed in a variety of ways to yield added-value materials for various applications, e.g., polymer composites. However, most lignocellulosic biomass is incinerated for energy. Typically, agricultural waste is left to decompose in the fields, causing problems such as greenhouse gas release, attracting insects and rodents, and impacting soil fertility. This study aims to valorise nonedible tomato waste with no commercial value in Additive Manufacturing (AM) to create sustainable, cost-effective and added-value PLA composites. Fused Filament Fabrication (FFF) filaments with 5 and 10 wt.% tomato stem powder (TSP) were developed, and 3D-printed specimens were tested. Mechanical testing showed consistent tensile properties with 5% TSP addition, while flexural strength decreased, possibly due to void formation. Dynamic mechanical analysis (DMA) indicated changes in storage modulus and damping factor with TSP addition. Notably, the composites exhibited antioxidant activity, increasing with higher TSP content. These findings underscore the potential of agricultural waste utilization in FFF, offering insights into greener waste management practices and addressing challenges in mechanical performance and material compatibility. This research highlights the viability of integrating agricultural waste into filament-based AM, contributing to sustainable agricultural practices and promoting circular economy initiatives.

A new technique of additive prototyping filament volumetric nanostructuring based on the high-speed mechanical mixing of acrylonitrile-butadiene-styrene (ABS) copolymer granules and single-walled carbon nanotube (CNT) powder (without prior dispersion in solvents) is considered. The morphological spectra of scanning electron microscopy (SEM) images of nanostructured filament slice surfaces were obtained and characterized with the original mathematical simulation. The relations of structural changes in the "ingredient-matrix" polymer system with dielectric and mechanical properties of the ABS-based filaments were established. The supplementation of 1.5 mass.% of CNT powder to the ABS filament composition leads to the tensile strength increasing from 36 ± 2 to 42 ± 2 MPa. It is shown that the greater the average biharmonic amplitude and the morphological spectrum localization radius of the slice surfaces' SEM images, the lower the electrical resistance of the corresponding nanostructured filaments. The possibility of carbon nanotube-modified filament functional layers forming using the extrusion additive prototyping technique (FFF) on the surface of plasma-chemically modified PET substrates (for the creation of load cell elements) is experimentally demonstrated.

This article examines the mechanical properties and compatibility of selected composite materials produced with RP technology and the FFF-fused filament fabrication process. The article scales sophisticated modern materials based on PLA-polylactic acid-plastic and its composite variants. The research is carried out on the 3D FFF printer Felix 3.1 with a dual extruder, which works on the "open-source" principle. In this research, elements of the paradigm and methodology of the processing technology for RP were applied; they were implemented according to EN ISO 527 and ISO 2602 standards. The aim of this study was to investigate the impact of 3D-printing strategy on the mechanical properties of 5 types of PLA composites. The results of this research solve the material compatibility problem, primarily through experimental testing of different combinations of filaments in different printing directions. Analysis of the experimental data showed correlations between the choice of printing strategy and mechanical properties, mainly tensile strength of the selected filaments. The research results show the influence of the printing orientation on mechanical properties of 3D printed samples: parts extruded in length orientation showed higher values of tensile strength compared to parts made in width and height. The CarbonPLA material exhibited 10 times higher tensile strength when printed in length compared to samples.

Experimental research of the moisture sorption process of 12 typical filaments used for FFF was performed in atmospheres with a relative humidity from 16 to 97% at room temperature. Materials with high moisture sorption capacity were revealed. Fick's diffusion model was applied to all tested materials, and a set of sorption parameters was found. The solution of Fick's second equation for the two-dimensional cylinder was obtained in series form. Moisture sorption isotherms were obtained and classified. Moisture diffusivity dependence on relative humidity was evaluated. The diffusion coefficient was independent of the relative humidity of the atmosphere for six materials. It essentially decreased for four materials and grew for the other two. Swelling strain changed linearly with the moisture content of the materials and reached up to 0.5% for some of them. The degree of degradation of the elastic modulus and the strength of the filaments due to moisture absorption were estimated. All tested materials were classified as having a low (changes ca. 2-4% or less), moderate (5-9%), or high sensitivity to water (more than 10%) by their reduction in mechanical properties. This reduction in stiffness and strength with absorbed moisture should be considered for responsible applications.

The amount of wasted polylactic acid (PLA) is increasing because 3D printing services are an increasingly popular offering in many fields. The PLA is widely employed in the fused deposition modeling (FDM) since it is an environmentally friendly polymer. However, failed prototypes or physical models can generate substantial waste. In this study, the feasibility of recycling PLA waste plastic and re-extruded it into new PLA filaments was investigated. An automatic PLA filament extruder was first developed for fabricating new PLA filaments. This paper also discusses the process, challenges, and benefits of recycling PLA waste plastic in an effort to fabricate new PLA filaments more sustainable. It was found that it was possible to fabricate PLA filament using recycled PLA waste plastic. The production cost is only 60% of the commercially available PLA filament. The tensile strength of the developed PLA filament is approximately 1.1 times that of the commercially available PLA filament. The design of experiments approach was employed to investigate the optimal process parameters for fabricating PLA filaments. The most important control factor affecting the diameter of PLA filament is the barrel temperature, followed by recycled material addition ratio, extrusion speed, and cooling distance. The optimal process parameters for fabricating PLA filament with a diameter of 1.7 mm include the barrel temperature of 184 °C, extrusion speed of 490 mm/min, cooling distance of 57.5 mm, and recycled material addition ratio of 40%.

Linseed oil was graft modified with maleic anhydride and introduced into alginate by co-extrusion, producing alginate hybrid filaments. A straightforward grafting of maleic anhydride onto the oil backbone produced the modified oil. Additional esterification with n -dodecanol was also investigated. The structures of the modified oils were verified with 2D-NMR. The modified oil was mixed with alginate and extruded into CaCl 2 , forming thin filaments with diameters in the 130-260 μm range. The impact of oil integration into the alginate filaments was assessed, with special emphasis on stress-at-break, and compared to values predicted by an empirical model relating the "stress to alginate concentration" ratio to prevailing conditions during filament drawing. Analogous alginate filaments were prepared with hydrochloric-, oxalic- and phytic acid calcium salts for comparison with alginate-oil hybrids to reveal the induced impact, with respect to the composition and charge, on the tensile performance.

In this study, wet-spun filaments were prepared using lignocellulose nanofibril (LCNF), with 6.0% and 13.0% of hemicellulose and lignin, respectively, holocellulose nanofibril (HCNF), with 37% hemicellulose, and nearly purified-cellulose nanofibril (NP-CNF) through wet-disk milling followed by high-pressure homogenization. The diameter was observed to increase in the order of NP-CNF ≤ HCNF < LCNF. The removal of lignin improved the defibrillation efficiency, thus increasing the specific surface area and filtration time. All samples showed the typical X-ray diffraction pattern of cellulose I. The orientation of CNFs in the wet-spun filaments was observed to increase at a low concentration of CNF suspensions and high spinning rate. The increase in the CNF orientation improved the tensile strength and elastic modulus of the wet-spun filaments. The tensile strength of the wet-spun filaments decreased in the order of HCNF > NP-CNF > LCNF.

In this study, Polyamide 12 (PA12) powder recycled after selective laser sintering (SLS) was made into filaments for fused deposition modelling (FDM). Compared with fresh PA12, the melt flow rate (MFR) of the recycled PA12 powder decreased by 77%, but the mechanical properties were only slightly reduced. In FDM, the printing speed and building orientation were changed, and the performance of the printed parts was tested. If the printing speed is too fast or too slow, the mechanical properties of the parts will be affected, and there is an optimal speed range. The tensile strength, flexural modulus, and impact strength of a printed test sample made from recycled powder reached 95%, 85%, and 87% of an x -direction test sample made from fresh PA12, respectively. For test samples printed from different orientations, the mechanical properties of the test samples printed in the x -direction were the best, while the crystallization performance was the opposite. Scanning electron microscope (SEM) images show that the printed test sample had good compactness and mechanical properties, and the delamination phenomenon was basically not observed.