Development of Graphene/Recycled Carbon Fiber-Reinforced PLA Composites for MEX Printing and Dry Machinability Analysis

Material extrusion (MEX) is an additive manufacturing process used for 3D printing thermoplastic-based polymers, including single polymers, blends, and reinforced polymer composites (RPCs). RPCs are highly valued in various industries for their exceptional properties. The surface finish of RPC MEX-printed parts is high due to the process-related layering nature and the materials' properties. This study explores RPC development for MEX printing and the potential of dry milling post-processing to enhance the MEX-printed part's surface quality. RPC MEX filaments were developed by incorporating graphene nanoplatelets (GNPs) and/or recycled-carbon fibers (rCFs) into a polylactic acid (PLA) matrix. The filaments, including pure PLA and various GNPs-PLA composites, rCF-PLA, and rCF-GNPs-PLA, were developed through ball mill mixing and melt extrusion. Tensile tests were performed to assess the mechanical properties of the developed materials. Dry milling post-processing was carried out to assess the machinability, with the aim of enhancing the MEX-printed part's surface quality. The results revealed that adding GNPs into PLA showed no considerable enhancements in the tensile properties of the fabricated RPCs, which is contrary to several existing studies. Dry milling showed an enhanced surface quality of MEX-printed parts in terms of surface roughness (Sa and Sz) and the absence of defects such as delamination and layer lines. Adding GNPs into PLA facilitated the dry machining of PLA, resulting in reduced surface asperities compared to pure PLA. Also, there was no observation of pulled-out, realigned, or naked rCFs, which indicates good machinability. Adding GNPs also suppressed the formation of voids around the rCFs during the dry milling. This study provides insights into machining 3D-printed polymer composites to enhance their surface quality.