Valorization of Polymethylmethacrylate Scrap Reinforced with Nano Carbon Black with Optimized Ratio in Extrusion-Based Additive Manufacturing

To promote environmental sustainability, this research investigated the potential of utilizing recycled polymethylmethacrylate (PMMA) as raw material in material extrusion (MEX) additive manufacturing (AM). To enhance its mechanical response, carbon black (CB) was employed as the filler in nanocomposite formation. Filament extrusion of the mixture at different concentrations produced printable feedstocks for MEX AM. Rheological analysis (viscosity and material flow rate) showed that the CB introduction to the matrix was beneficial for consistent layer deposition, while differential scanning calorimetry and thermogravimetric analyses verified the thermal stability of the nanocomposites during processing. Mechanical properties were optimized, with increases in modulus (27.8% and 25.8%, respectively, in tensile and bending loadings) and tensile strength at optimal CB loadings. Dynamic mechanical analysis revealed the viscoelastic response of the nanocomposites. Raman and energy dispersive spectroscopy provided element-related insights. Surface morphology and parts structure were observed employing scanning electron microscopy and micro-computed tomography, respectively, revealing a positive impact on the AM parts due to the CB presence in the nanocomposites. The 4 wt.% in CB content nanocomposite was the optimum one. This research pioneers the development of new sustainable nanocomposite filaments and highlights the potential of next-generation MEX-based AM.