Sustainable Metal and Natural Materials Composite Filaments for 3D Printing

Sustainble Reinforcement of Filament

Manufacturing

NAMIC hub@SIT

Fused Deposition Modelling (FDM)/Fused Filament Fabrication (FFF) is a popular and widely used 3D printing technology. However, thermoplastic-based materials such as ABS or PLA for printing do present a challenge regarding material properties and sustainability.
The use of materials with limited mechanical properties presents a significant challenge to create products that last.
Recycling discarded materials with a simple and effective solution that addresses the waste crisis while increasing the economic value of discarded materials.

To investigate the potential of using reinforcement materials to enhance the mechanical properties of bio-based PLA polymer.
To explore the possibility of improving the electrical and thermal properties of the polymer matrix by incorporating reinforcement materials.
To evaluate the effectiveness of metal powder and natural materials, such as Pineapple Leaf Fibre, Chitin, Chitosan, Coir Fibre and Waste Coffee Powder, as reinforcement materials for bio-based PLA polymer.
To analyze the effect of different reinforcement materials on the tensile and flexural properties of the bio-based PLA polymer matrix.

Developing a new generation of sustainable filament with enhanced mechanical, electrical and thermal properties, using bio-based PLA polymer matrix reinforced with suitable natural and metal-based materials.
Developing new methods for producing metal-based filaments suitable for FFF/FDM, using metal powders mixed with a removable binder or polymers such as PLA.
Fabrication of dense metal parts or hybrid metal/polymer parts using the metal-based filaments produced through the developed methods.
Preliminary studies have demonstrated promising results for the densification of stainless steel samples, achieving 80% densification after sintering at 1090 degrees Celsius and ultimate compressive strength of approximately 170MPa.