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<p>The growing demand for lightweight, sustainable materials in additive manufacturing has driven the development of advanced polymer composites with enhanced mechanical performance. In this study, PLA-cenospheres composite filaments were fabricated via pellet extrusion to enhance mechanical strength while promoting eco-friendly material use. The incorporation of 10 wt% cenospheres significantly improved mechanical and surface characteristics, with tensile strength increasing from 40&#xa0;MPa to 49&#xa0;MPa and tensile modulus from 1650&#xa0;MPa to 1820&#xa0;MPa. Shore D hardness improved from 65 to 75, while compressive strength increased from 48&#xa0;MPa to 62&#xa0;MPa, attributed to the effective stress transfer provided by the hollow fillers. The density decreased by 11.1% (1.26 to 1.12&#xa0;g/cm³), and surface roughness (Ra) increased from 6.3&#xa0;μm to 7.2&#xa0;μm. SEM and EDS analyses confirmed uniform filler dispersion, strong interfacial adhesion, and minimal voids. These results establish the PLA-cenospheres composite as a sustainable, lightweight material suitable for structural applications in aerospace, automotive, and drone manufacturing.</p>

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Mechanical evaluation of 3D printed PLA-cenosphere composite

  • 期刊论文

  • 发表日期：

    2026年8月5日

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  • Ayushi Gupta,
  • Sonika Sahu,
  • Anish Sachdeva,
  • Narendra Kumar

摘要

The growing demand for lightweight, sustainable materials in additive manufacturing has driven the development of advanced polymer composites with enhanced mechanical performance. In this study, PLA-cenospheres composite filaments were fabricated via pellet extrusion to enhance mechanical strength while promoting eco-friendly material use. The incorporation of 10 wt% cenospheres significantly improved mechanical and surface characteristics, with tensile strength increasing from 40 MPa to 49 MPa and tensile modulus from 1650 MPa to 1820 MPa. Shore D hardness improved from 65 to 75, while compressive strength increased from 48 MPa to 62 MPa, attributed to the effective stress transfer provided by the hollow fillers. The density decreased by 11.1% (1.26 to 1.12 g/cm³), and surface roughness (Ra) increased from 6.3 μm to 7.2 μm. SEM and EDS analyses confirmed uniform filler dispersion, strong interfacial adhesion, and minimal voids. These results establish the PLA-cenospheres composite as a sustainable, lightweight material suitable for structural applications in aerospace, automotive, and drone manufacturing.