In the present work, investigations of the wettability, wear, and morphological study on 3D-printed polylactic acid (PLA)/molybdenum disulfide (MoS ₂ )-silicon carbide (SiC) based composite have been performed. In the first stage, the PLA/MoS ₂ -SiC composite was fabricated from the different types of filaments of 1.75 ± 0.10 mm size by taking MoS ₂ -SiC as reinforcement at various extrusion temperatures (150°C–160°C) and screw rotational speed (3–7 r/min) of the extruder setup. The Taguchi L9 orthogonal array was used to design the experiments for 3D printing by varying the filament type, range of nozzle temperature (200°C–210°C), and infill density (40%–90%). The pin-on-disk (POD) setup was used for measuring specific wear rate (SWR) and showed the lowest value of 0.00141 g/N-m when composites were 3D printed by taking filaments manufactured at the parametric combination of 160°C extruder temperature and 7 r/min rotational speed, while 3D printed at 210°C nozzle temperature and 40% infill density. Contact angle (CA) values indicated that the reinforcement of MoS ₂ and SiC in PLA resulted in hydrophilic surface formation due to morphology and increased roughness (including mean roughness (Sa), mean root square of the Z data (Sq), and the highest peak (Sz)). The significantly increased surface free energy (SFE) of MoS ₂ -SiC-reinforced PLA composite compared to pure PLA was reported which makes the prepared composite a promising candidate to be used for biocompatible implants with high wear resistance.

The 3D-printed rapid tools are being used in finishing operations such as drilling, milling, broaching, roller burnishing, and other finishing operations that need anti-wear plastic composite materials. Zirconium oxide (ZrO₂) is one of the ceramic materials which is highly appreciated due to its anti-wear properties. This study aims to develop the ZrO₂ ceramic particles reinforced acrylonitrile butadiene styrene (ABS) thermoplastic composite feedstock filaments for 3D printing of rapid tools. In the first stage, the multiple numbers (as per Taguchi L₉ orthogonal array (OA)) of ABS-ZrO₂ feedstock filaments were developed by varying the loading of ZrO2 in ABS matrix (2 wt.%, 4 wt.%, and 6 wt.%), processing temperature (200, 205 and 210°C), and rotation speed of screw (4, 6 and 8 RPM). The optimum setting obtained for manufacturing ABS-ZrO₂ composite feedstock filaments is the combination of 2% ZrO2 loading, 205°C processing temperature, and 6 RPM screw speed. In the next stage, fused filament fabrication (FFF) based 3D printing has been used to prepare the rapid tools. The wear test performed for 3D printed ABS-ZrO₂ composites rapid tools shows only .62% weight loss which is lower as compared to virgin ABS (.91% weight loss). The results of the study are supported by fracture analysis, morphology, and mechanical properties.

Fused deposition modeling -based three-dimensional printing techniques, when merged with the investment casting process, is one of the most innovative techniques for developing functionally graded metal–matrix composites in high-performance industrial applications. In this study, Al–Al₂O₃matrix composites have been prepared by the combined route of fused deposition modeling and modified investment casting processes. In the first step, the Al–Al₂O₃particles have been reinforced into nylon 6 thermoplastics for the preparation of fused deposition modeling-based feedstock filaments (in two configurations: C1 (60% nylon 6–30% Al–10% Al₂O₃) and C2 (60% nylon 6–28% Al–12% Al₂O₃). In the next step, the investment casting patterns of the fused deposition modeling process of nylon 6–Al–Al₂O₃composites were prepared. Furthermore, the investment casting has been performed by controlling the proportion of nylon 6–Al–Al₂O₃, the volume of pattern, the density of pattern, barrel finishing media weight, barrel fining time, and number of mold wall layers considering Taguchi L₁₈-based experimental design. Finally, the functional aluminum matrix composites were subjected to testing to investigate average surface roughness ( R_a), deviation inside the cube, average wear, and average hardness. The study results have suggested that maintaining a higher proportion of Al₂O₃in three-dimensional printed parts leads to higher R_a, higher dimensional deviation, and higher hardness of investment cast parts. On the contrary, solid patterns have provided low wear rates and low-density patterns resulting in increased wear rates in final investment casted products. Furthermore, the responses are optimized concurrently with the “technique for order of preference by similarity to ideal solution–Taguchi” technique while considering the analytical hierarchical process and entropy weights of significance.