Mechanical Performance of <scp>PLA</scp> ‐ <scp>MWCNT</scp> Nanocomposite Developed by Ecofriendly Hybrid Filament Processing Method for Fused Deposition Modeling Applications

ABSTRACT The synthesis of biodegradable polylactic acid (PLA)‐based nanocomposites has received considerable interest for sustainable engineering applications. However, the uniform dispersion of nanofillers and the structural integrity of the polymer matrix are still challenging. In this research, a new green hybrid fabrication process was utilized to fabricate polylactic acid (PLA) reinforced with multiwall carbon nanotubes (MWCNTs) for 3D printing purposes. The approach entailed simultaneous mixing of precursors using ultrasonication and magnetic stirring, which was then subjected to subsequent solution casting and melt extrusion. This ensured homogeneous dispersion of the MWCNTs in the PLA matrix. The weight percentage of MWCNTs was also varied at 0.5, 0.75, and 1 wt.%, along with a neat PLA sample for reference. Detailed characterization methods, such as scanning electron microscopy (SEM), X‐ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), differential scanning calorimetry (DSC), and thermogravimetric analysis (TGA), were employed to study the structural, thermal, and morphological characteristics of the composites. The ANSYS simulation results showed good agreement with experimental data, with deviations ranging from 4.9% to 6.7% across tensile, compressive, and flexural strengths. The findings exhibited increased mechanical strength, thermal stability, and enhanced structural integrity of PLA‐MWCNT nanocomposites over neat PLA. The designed fabrication method provides a scalable and environmentally friendly method for obtaining high‐performance polymer nanocomposites. These findings are of great promise in the area of biomedical implants, lightweight structural applications, and high‐end 3D printing, where increased mechanical properties and biodegradability are needed.