Polylactic acid‐based composite using fused filament fabrication: Process optimization and biomedical application

Abstract

Biopolymer-based composites, which are being employed extensively in biomedical applications have exceptional physical and mechanical properties. However, printing composites is a challenging task for biomedical applications. The current work highlights the impact of process parameters of fused filament fabrication (FFF) technology, that is, layer height, number of loops, nozzle temperature, and a nonprocess parameter, that is, weight percentage of alumina on ultimate tensile strength, ultimate flexural strength, and ultimate compression strength of polylactic acid (PLA)-alumina composite. Response surface methodology (RSM) has been implemented to construct the tests. The regression model demonstrated how various parameters and their interaction affected output responses. The surface plots for noticeable interactions have also been plotted. The outcome revealed that parameter control and optimization have vital impact on mechanical properties. The optimum value for maximum mechanical strengths has been obtained at layer height 0.1 mm, number of loops 4, nozzle temperature 195 C, and weight percentage of alumina as 1.5%. Later a case study has been performed with obtained optimized parameters with porous structures for biomedical applications and found that the properties such as surface finish, and dimensional accuracy were unaltered during the optimization process.

Sandwich structures based on fused filament fabrication 3D‐printed polylactic acid honeycomb and poly(vinylidene fluoride) nanocomposites for microwave absorbing applications

“…[34][35][36][37] Among several 3D printing technologies, FFF presents low cost, large amount of applicable materials, and straightforward operation. [38] The two most used thermoplastic polymers in FFF are acrylonitrile-butadiene-styrene (ABS) [39][40][41][42] and PLA [43][44][45] due to their rheological and thermal properties that are well suited for this process. Between them PLA is a long-lasting biodegradable, biocompatible polyester produced from renewable resources such as sugar cane, corn, and potato.…”

Investigations on effect of pore architectures of additively manufactured novel hydroxyapatite coated PLA/Al2O3 composite scaffold for bone tissue engineering

“…The scaffolds were printed with 0.1 mm layer height, four outer shells, printing speed 25 mm/sec, infill density of 100% with a straight-line infill pattern using a 0.4 mm brass nozzle. The process parameters were selected according to previous published studies (Choudhary et al , 2022). After reaching the desired temperatures, FDM machine followed the G codes and fabricated the scaffolds layer by layer.…”

Additive Manufacturing of Polymer‐Based Lubrication

“…The current study emphasizes the effects of fused filament fabrication (FFF) process parameters, such as layer height, ring number, and nozzle temperature, as well as non‐process parameters, such as alumina weight percentage, on ultimate tensile strength and elasticity. Strength and ultimate compressive strength of alumina and polylactic acid composite materials (PLA), [ 127 ] a response surface methodology (RSM) was used. Different factors' impacts and interactions on the output response are demonstrated via a regression model.…”