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<p>Polymer additive manufacturing is advancing rapidly due to its flexibility, innovation, and cost-effective prototyping. Polylactic acid (PLA), though widely used for its biodegradability and ease of processing, is limited by moderate strength, higher cost, low glass transition temperature, and moisture absorption. Reinforcing PLA with short fibers and fillers improves its properties, but progress is limited by scarce custom filaments and the high cost of microscale natural fibers. This study evaluates low-cost coconut shell powder (CSP) as reinforcement in PLA and its effect on thermo-mechanical properties and environmental durability for FDM applications. The mechanical performance of CSP-reinforced PLA is compared with PLA inorganic nanoclay filler combination. PLA pellets are mixed with CSP and twin-screw extruded into filaments and then FDM-printed into test specimens. Tensile and flexural properties are evaluated; UV aging evaluates durability; and FTIR, XRD, and DSC assess chemical and crystallinity changes. Mechanical tests reveal a 23% improvement in the tensile and 19% improvement in flexural properties over neat PLA. UV aging showed improved photodegradation resistance, while FTIR, XRD, and DSC indicated increased crystallinity and thermal stability. Coconut shell powder (CSP), an abundant agricultural waste, acts as a low-cost, sustainable filler that enhances PLA’s thermo-mechanical and anti-aging properties, supporting circular bio-composites.</p> Graphical Abstract <p></p>

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Enhancing 3D-Printed Polylactic Acid with Low-Cost Coconut Shell Powder for Better Mechanical Performance and Environmental Durability

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Ramachandran Velmurugan,
  • Shankar Krishnapillai,
  • Sunil Mathew Roy

摘要

Polymer additive manufacturing is advancing rapidly due to its flexibility, innovation, and cost-effective prototyping. Polylactic acid (PLA), though widely used for its biodegradability and ease of processing, is limited by moderate strength, higher cost, low glass transition temperature, and moisture absorption. Reinforcing PLA with short fibers and fillers improves its properties, but progress is limited by scarce custom filaments and the high cost of microscale natural fibers. This study evaluates low-cost coconut shell powder (CSP) as reinforcement in PLA and its effect on thermo-mechanical properties and environmental durability for FDM applications. The mechanical performance of CSP-reinforced PLA is compared with PLA inorganic nanoclay filler combination. PLA pellets are mixed with CSP and twin-screw extruded into filaments and then FDM-printed into test specimens. Tensile and flexural properties are evaluated; UV aging evaluates durability; and FTIR, XRD, and DSC assess chemical and crystallinity changes. Mechanical tests reveal a 23% improvement in the tensile and 19% improvement in flexural properties over neat PLA. UV aging showed improved photodegradation resistance, while FTIR, XRD, and DSC indicated increased crystallinity and thermal stability. Coconut shell powder (CSP), an abundant agricultural waste, acts as a low-cost, sustainable filler that enhances PLA’s thermo-mechanical and anti-aging properties, supporting circular bio-composites.

Graphical Abstract