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<p>Due to increasing global concerns about plastic waste and a greater emphasis on sustainability, there is a growing interest in using recycled plastics in additive manufacturing. Still, the weak strength of additively manufactured components with recycled material remains an ongoing challenge. In the realm of 3D printing, the incorporation of additives has shown huge potential as an effective means to enhance the performance of recycled materials. Due to low crystallinity of recycled polylactic acid (rPLA) material, 3D-printed products with rPLA exhibit the poor thermo-mechanical properties which restrict its applications in many fields. To overcome this problem, in the present work, the authors focused on using the waste 3D-printed PLA parts and silver–graphite (Ag–Gr) as reinforced material (varying 1, 2.5 and 5 wt.%) to develop the recycled-reinforced composite feedstock filament (diameter: 1.75 ± 0.05&#xa0;mm) through extrusion process for fused-filament fabrication process. To assess the suitability and feasibility of the developed composite filament for additive manufacturing, a range of characterization techniques are employed, i.e., melt flow index (MFI) measurements to evaluate processability, Fourier transform infrared spectroscopy (FTIR) for chemical analysis, scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS) for morphological and elemental analysis, X-ray diffraction (XRD) for crystallinity assessment, and differential scanning calorimetry (DSC) for thermal characterization. With the incorporation of Ag–Gr (5% wt.) in rPLA, no nozzle clogging was detected during 3D-printing process, providing a superior quality of 3D printing of samples. The 3D-printed samples with PLA, rPLA and different wt.% combinations (from 1 to 5%) of Ag–Gr in rPLA were tested for tensile strength. The maximum tensile strength was observed to be 27.86&#xa0;MPa for the sample printed with Ag–Gr (5%)/rPLA (95%) filament, which was 73.47% higher than those of the rPLA filament. The increase in crystallinity of the filaments was observed by XRD analysis due to the nucleating effect of Ag–Gr. The maximum crystallinity of 12.23% was observed in the filament containing 5 wt% Ag–Gr, which was 84.46% higher than those of the rPLA filament. The characterization results reveal that chemical properties remain consistent, but the mechanical properties are improved with the incorporation of Ag–Gr in rPLA.</p>

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Development and characterization of Ag–Gr reinforced rPLA feedstock filament for additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年3月18日

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  • Jatinder Singh,
  • Rakesh Kumar

摘要

Due to increasing global concerns about plastic waste and a greater emphasis on sustainability, there is a growing interest in using recycled plastics in additive manufacturing. Still, the weak strength of additively manufactured components with recycled material remains an ongoing challenge. In the realm of 3D printing, the incorporation of additives has shown huge potential as an effective means to enhance the performance of recycled materials. Due to low crystallinity of recycled polylactic acid (rPLA) material, 3D-printed products with rPLA exhibit the poor thermo-mechanical properties which restrict its applications in many fields. To overcome this problem, in the present work, the authors focused on using the waste 3D-printed PLA parts and silver–graphite (Ag–Gr) as reinforced material (varying 1, 2.5 and 5 wt.%) to develop the recycled-reinforced composite feedstock filament (diameter: 1.75 ± 0.05 mm) through extrusion process for fused-filament fabrication process. To assess the suitability and feasibility of the developed composite filament for additive manufacturing, a range of characterization techniques are employed, i.e., melt flow index (MFI) measurements to evaluate processability, Fourier transform infrared spectroscopy (FTIR) for chemical analysis, scanning electron microscopy (SEM) with energy-dispersive X-ray spectroscopy (EDS) for morphological and elemental analysis, X-ray diffraction (XRD) for crystallinity assessment, and differential scanning calorimetry (DSC) for thermal characterization. With the incorporation of Ag–Gr (5% wt.) in rPLA, no nozzle clogging was detected during 3D-printing process, providing a superior quality of 3D printing of samples. The 3D-printed samples with PLA, rPLA and different wt.% combinations (from 1 to 5%) of Ag–Gr in rPLA were tested for tensile strength. The maximum tensile strength was observed to be 27.86 MPa for the sample printed with Ag–Gr (5%)/rPLA (95%) filament, which was 73.47% higher than those of the rPLA filament. The increase in crystallinity of the filaments was observed by XRD analysis due to the nucleating effect of Ag–Gr. The maximum crystallinity of 12.23% was observed in the filament containing 5 wt% Ag–Gr, which was 84.46% higher than those of the rPLA filament. The characterization results reveal that chemical properties remain consistent, but the mechanical properties are improved with the incorporation of Ag–Gr in rPLA.