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Materials Science in Additive Manufacturing Natural composite filaments for 3D-Print

Table 4. Specification, composition, characteristics, and applications of commonly used composite‑based biofilament materials
in the FDM process
S. Specification of Composition Characteristics Applications References
No. composite‑based
biofilaments
1 PLA+PHB+plasticizer 60 wt.% of PHB Displayed satisfactory Designed for use in eco-friendly 64
blends 15 wt.% of plasticizer blends degradation application
2 CNF+PLA+PEG 2.5 wt.% of CNF Fulfilled requirements for FDM Can be considered for the 66
3D printing high-value utilization of CNF
in 3D printing for consumer
product applications
3 PLLA+flax fiber 10 wt.% of flax fibers Reinforced filament material with Potential to successfully develop 99
biodegradable attributes fully compostable filaments
4 PLA+lignin 5 wt.% of lignin Optimum wt.% of lignin to Potential to convert lignin into 69
develop 3D-printed filament new high-value products
5 PLA+inorganic nanotubes 0.5 wt.% of inorganic Printing flexibility observed in Can be used in custom-made 100
nanotubes the FFF process biodegradable scaffolds of soft
implants
6 PLA+cork 5 wt.% of cork Specific modulus and specific Cork–PLA composites have 101
tensile strength properties potential for use in light and
improved as the cork content impact-resistant 3D structures
increased
7 PLA+wood 10 – 20 wt.% of fiber content Mechanical properties are Can be considered to produce 102
strongly dependent on printing biocomposites with a faster
orientation due to fiber moisture-induced bending
anisotropy response
8 PLA+continuous flax fibers Continuous flax yarns with a Increased tensile modulus and High-measured performance 95
linear density of 68 Tex strength values observed opens up 3D-printed
biocomposites to further
structural applications
Abbreviations: CNF: Cellulose nanofibrils; FDM: Fused deposition modeling; FFF: Fused filament fabrication; PEG: Polyethylene glycol;
PHB: Polyhydroxy butyrate; PLA: Polylactic acid; PLLA: Poly-l-lactic acid.

the PHA matrix. The optimum mechanical performance as the frequent obstruction of the nozzle is minimized by
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of the mentioned biocomposite filament, which exceeded the utilization of homogenous filament material. 71,86 The
both the tensile strength at break and Young’s modulus of degree of homogeneity in NFRCFs, specifically between
neat PHA, was found to occur at a weight percentage of the filler and polymer matrix, depends on a few notable
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fiber content of 20%. In another investigation involving factors ranging from the manufacturing process to the
the use of hemp and New Zealand flax for the fabrication composition of the filament mix.
of NFRCF, the optimum mechanical properties in terms In terms of the manufacturing process, extrusion was
of their Young’s modulus were also observed to occur at a found to be the most adopted process to produce filament
fiber content of 20%. Moreover, the discrepancy in terms materials with the best results. 64,71 As displayed in Figure 10,
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of mechanical performance observed between the two the extrusion process was successfully considered in
composites was attributed to the finer fiber having a better 66
aspect ratio that yielded better results. 63 a previous study to generate biofilament materials.
However, the extrusion process, in turn, was dependent
4.4. How to achieve homogeneous NFRC filament? on the filament melt index. For the best extrusion and
generation of high-quality NFRCFs, an optimum melt
The quality of 3D prints largely depends on the nature and
characteristics of the filament material in the FDM process. index is identified. The selected melt index is not excessively
One such key characteristic is the degree of homogeneity high so as to prevent the degradation of natural fibers, as
in the filament material. The more homogenous the well as not exceedingly low as this could lead to clogging
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issues.
92,104
filament material, the better the quality of the 3D prints
in terms of their layers’ uniformity, layer adhesion, and Besides the manufacturing process, a homogeneous
surface finish. The overall FDM process is also impacted mix of the NFRCFs could be further achieved by enhancing
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Volume 4 Issue 1 (2025) 12 doi: 10.36922/msam.8533