Rheological Characterization and Printability of Polylactide (PLA)-Alumina (Al₂O₃) Filaments for Fused Deposition Modeling (FDM)

This article presents the study of the rheological properties and the printability of produced ceramic-polymer filaments using fused deposition method (FDM) 3D printing technology. Powder mixtures with an alumina content of 50 to 70 vol.% were fabricated by a wet processing route. A series of rheological experiments of the obtained mixtures were conducted in the temperature range from 200 to 220 °C for the commercial polylactide (PLA) powder and from 200 to 240 °C for ceramic-polymer, which corresponds to the recommended temperatures for 3D printing of commercial PLA filaments. The composition with the maximum content of alumina leads to a powdery material in which the molten polymer is insufficient to measure the rheological properties. In spite of this, the filaments were prepared from all the obtained mixtures with a tabletop single-screw extruder, the diameter and surface profile of which were analyzed. As the ceramic content increased, the diameter and surface roughness of the filaments increased. Therefore, it was only possible to print an object from a filament with the lowest ceramic content. However, the print quality of the 3D printed objects from the fabricated ceramic-polymer filament is worse (imperfect form, defects between layers) compared to the commercial PLA filament. To eliminate such defects in the future, it is necessary to conduct additional research on the development of printing modes and possibly modify the software and components of the 3D printer