Fabrication and Characterization of PLA-Based Ceramic Composite Filaments for FDM 3D Printing

This study investigated the fabrication and characterization of polylactic acid (PLA)-based ceramic composite filaments for fused deposition modeling (FDM) 3D printing. Boron carbide (B4C) and silicon carbide (SiC) were incorporated into PLA at various weight fractions (1–40 wt. % for B4C and 1–20 wt. % for SiC) to produce composite filaments using a commercial extruder. The rheological properties, thermal stability, and printability of the filaments were evaluated. Filaments with low ceramic content exhibited satisfactory quality, whereas those with higher loadings required reprocessing to improve their dimensional stability and surface morphology. Successful printing was achieved with SiC contents of up to 8 wt. % using single-extruded filaments and up to 20 wt. % using double-extruded filaments. Rheological tests revealed that filaments with low ceramic content exhibited shear-thinning behavior, whereas those with higher loadings displayed nearly Newtonian-like behavior. Thermal analysis using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) determined the optimal processing temperature range for the composite filaments to be between 200 °C and 270 °C. High-temperature microscopy was used to study the temperature behavior of the B4C-containing filaments and set the optimum printing temperature. The results demonstrate the feasibility of producing PLA-based ceramic composite filaments for FDM 3D printing with the potential to tailor the thermal and functional properties of the printed parts for specific applications.