The main aim of this research was the preparation of a polymer–ceramic composite with PA-12 as the polymer matrix and modified aluminosilicate cenospheres (CSs) as the ceramic filler. The CSs were subjected to an early purification and cleaning process, which was also taken as a second objective. The CSs were surface modified by a two-step process: (1) etching in Piranha solution and (2) silanization in 3-aminopropyltriethoxysilane. The composite was made for 3D printing by FDM. Raw and modified CSs and a composite with PA-12 were subjected to the following tests: surface development including pores (BET), real density (HP), chemical composition and morphology (SEM/EDS, FTIR), grain analysis (PSD), phase composition (XRD), hardness (HV), and static tensile tests. The composites were subjected to soaking under simulated body fluid (SBF) conditions in artificial saliva for 14, 21, and 29 days. Compared to pure PA-12, PA-12_CS had generally better mechanical properties and was more resistant to SBF at elevated temperatures and soaking times. These results showed this material has potential for use in biomedical applications. These results also showed the necessity of developing a kinetic aging model for aging in different liquids to verify the true value of this material.

This paper investigates new approaches for the blending and plastification of ceramic powder with a binder to form fused deposition of ceramic (FDC) feedstock. The fabrication of highly filled ceramic filaments was accomplished using the granulation by agitation technique, followed by twin-screw extruder homogenization and single-screw extruder filament extrusion. The feedstocks are based on alumina (Al2O3) powders, which were prepared with an industrial binder through three different routes: wet granulation, melt granulation and melt granulation with a suspension. After printing cubic samples and tensile test specimens on a commercial fused deposition modelling (FDM) printer, the properties of the resulting green-body and sintered parts were investigated. The green-body mechanical values are compared with results from commercially available filaments. Mixing the binder with the alumina powder and surfactant in a suspension produces the lowest viscosity and the best elongation at break.