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Owing to its robustness, ability to achieve complex geometries, and ease of use, 3D printing has become one of the noteworthy applications in the field of engineering. Polycarbonate has become a thermoplastic of interest due to its excellent mechanical and optical properties. Especially when infused with nanosilica, polycarbonate becomes a potential candidate for 3D printing with enhanced properties. Polycarbonate nanocomposite filaments infused with AEROSIL (nanosilica) have been melt extruded with various filler loadings of 0.5, 1, and 3 wt% and are then 3D printed. The thermal analysis of the filaments has shown that thermal stability of the filaments increases with increase in filler loading. Tensile tests have shown that addition of nanosilica have enhanced the mechanical properties of the filaments as well as 3D printed films. The addition of silica in low concentrations exhibit higher transmittance of UV light, as silica restricts the mobility of polycarbonate. Despite 3D printing causing voids in bulk materials, silica at low concentration (0.5 and 1 wt%) can improve the mechanical and optical properties. These improvements are promising for applications in thin film interfaces and the automotive industry.

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