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<p>Advancements in fused filament fabrication (FFF), a form of additive manufacturing, have spurred interest in eco-friendly polymer composites. This study hypothesizes that incorporating biochar, a carbon-rich waste-derived filler, into polylactic acid (PLA) will enhance wear resistance, thermal conductivity, and mechanical properties. To test this hypothesis, PLA pellets were fabricated with 5 and 10&#xa0;wt.% PLA–biochar using twin-screw extrusion and printed via FFF. Standard test specimens (one sample per test owing to material and cost constraints) were evaluated for mechanical, tribological, and thermal performance in accordance with ASTM standards. Tensile strength decreased from 53.33&#xa0;MPa (pure PLA) to 12.83&#xa0;MPa (5% biochar) but recovered slightly to 14.30&#xa0;MPa at 10% biochar. Flexural strength followed a similar trend, decreasing from 81.33 to 28.47&#xa0;MPa (5%) and then increasing to 36.60&#xa0;MPa (10%). Wear resistance improved significantly, with the wear rate dropping from 0.375 to 0.125&#xa0;µm/s and the coefficient of friction falling from 0.375 to 0.095. Thermal conductivity rose from 0.1765 to 0.2414&#xa0;W/mK at 10% biochar content. Scanning electron microscopic analysis revealed lowered material loss and improved surface integrity in biochar-filled samples. These results confirm that biochar enhances the functional properties of PLA composites, particularly in terms of wear resistance and thermal conductivity, supporting its use in sustainable, high-performance FFF applications.</p>

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Fabrication and Comprehensive Characterization of Biochar-Enhanced PLA Composite 3D Filament

  • 期刊论文

  • 发表日期：

    2026年2月4日

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  • M. Sumalatha,
  • K. Pranay Rahul,
  • M. Bala Chennaiah,
  • B. Bhanu Teja,
  • G. Ravi Teja

摘要

Advancements in fused filament fabrication (FFF), a form of additive manufacturing, have spurred interest in eco-friendly polymer composites. This study hypothesizes that incorporating biochar, a carbon-rich waste-derived filler, into polylactic acid (PLA) will enhance wear resistance, thermal conductivity, and mechanical properties. To test this hypothesis, PLA pellets were fabricated with 5 and 10 wt.% PLA–biochar using twin-screw extrusion and printed via FFF. Standard test specimens (one sample per test owing to material and cost constraints) were evaluated for mechanical, tribological, and thermal performance in accordance with ASTM standards. Tensile strength decreased from 53.33 MPa (pure PLA) to 12.83 MPa (5% biochar) but recovered slightly to 14.30 MPa at 10% biochar. Flexural strength followed a similar trend, decreasing from 81.33 to 28.47 MPa (5%) and then increasing to 36.60 MPa (10%). Wear resistance improved significantly, with the wear rate dropping from 0.375 to 0.125 µm/s and the coefficient of friction falling from 0.375 to 0.095. Thermal conductivity rose from 0.1765 to 0.2414 W/mK at 10% biochar content. Scanning electron microscopic analysis revealed lowered material loss and improved surface integrity in biochar-filled samples. These results confirm that biochar enhances the functional properties of PLA composites, particularly in terms of wear resistance and thermal conductivity, supporting its use in sustainable, high-performance FFF applications.