Based on differential scanning calorimetry (DSC), X-ray diffraction (XRD) analysis, polarizing microscope (POM), and scanning electron microscopy (SEM) analysis, strategies to close the gap on applying conventional processing optimizations for the field of 3D printing and to specifically increase the mechanical performance of extrusion-based additive manufacturing of poly(lactic acid) (PLA) filaments by annealing and/or blending with poly(3-hydroxybutyrate) (PHB) were reported. For filament printing at 210 °C, the PLA crystallinity increased significantly upon annealing. Specifically, for 2 h of annealing at 100 °C, the fracture surface became sufficiently coarse such that the PLA notched impact strength increased significantly (15 kJ m⁻²). The Vicat softening temperature (VST) increased to 160 °C, starting from an annealing time of 0.5 h. Similar increases in VST were obtained by blending with PHB (20 wt.%) at a lower printing temperature of 190 °C due to crystallization control. For the blend, the strain at break increased due to the presence of a second phase, with annealing only relevant for enhancing the modulus.

The combined influences of crystallinity and reactive compatibilizer—a multifunctional epoxide (ADR)—on morphology, tensile performance, and heat resistance of polylactide/thermoplastic polyester elastomer (PLA/TPEE) (80/20) blends were investigated. Annealing involved an isothermal cold crystallization of PLA matrix was performed to increase crystallinity of the samples. First, isothermal cold crystallization kinetics were investigated using differential scanning calorimetry measurement. It was found that the addition of ADR decreased the crystallization rate of the samples. The maximum crystallinity of the annealed samples also decreased from 40% to 34% while ADR loading increased from zero to 1.0 phr. Furthermore, influence of crystallinity on mechanical performances of the PLA/TPEE sample was researched. The heat resistance of the sample showed a significant enhancement while increasing its crystallinity. Meanwhile, the tensile ductility of the crystallized PLA/TPEE sample became very poor due to the embrittlement with increased crystallinity and the incompatibility between PLA and TPEE. However, the annealed PLA/TPEE/ADR samples with high crystallinity kept a higher tensile ductility because ADR greatly improved the interfacial compatibility. Differences in tensile fracture behaviors of the quenched and annealed PLA/TPEE samples with and without ADR were discussed in detail. At last, crystallized PLA/TPEE/ADR blends with excellent heat resistance and high tensile ductility were obtained by annealing and reactive compatibilization.

To investigate the influence of varying concentrations and types of carbon fiber (CF) on the mechanical properties of polyamide 6 (PA6) composites, this study explores the mechanical properties of PA6 composites with various CF types and quantities. The micro-morphology of the composites and the CF length distribution were characterized. The results indicate that the inclusion of carbon fibers significantly enhances the tensile, flexural, and notched impact strengths of PA6. Specifically, when about 30 wt% of CF T300 was added, the tensile and flexural strength of the composite reached a maximum of 166 MPa and 224 MPa, respectively, representing increases of 236.6% and 229.6%, respectively, compared to pure PA6. The maximum flexural modulus achieved 14.6 GPa, which was six times as large as that of pure PA6. Moreover, the CF length in the PA6 matrix follows a near-Gaussian distribution. A proper CF length and orientation, along with strong interfacial bonding between CF and the PA6 matrix, contribute to improved mechanical properties. The overall performance of T700-reinforced composites is better than that of T300-reinforced ones due to T700’s higher precursor strength and better fiber-length retention. This study provides guidance for fabricating high-performance PA6 composites.

In many fused filament fabrication (FFF) processes, commercial printers are used, but rarely are printer settings transferred from one commercial printer to the other to give similar final tensile part performance. Here, we report such translation going from the Felix 3.0 to Prusa i3 MK3 printer by adjusting the flow rate and overlap of strands, utilizing an in-house developed blend of polylactic acid (PLA) and poly(butylene adipate-co-terephthalate) (PBAT). We perform a sensitivity analysis for the Prusa printer, covering variations in nozzle temperature, nozzle diameter, layer thickness, and printing speed (T_nozzle, d_nozzle, LT, and v_print), aiming at minimizing anisotropy and improving interlayer bonding. Higher mass, larger width, and thickness are obtained with larger d_nozzle, lower v_print, higher LT, and higher T_nozzle. A higher v_print results in less tensile strain at break, but it remains at a high strain value for samples printed with d_nozzle equal to 0.5 mm. v_print has no significant effect on the tensile modulus and tensile and impact strength of the samples. If LT is fixed, an increased d_nozzle is beneficial for the tensile strength, ductility, and impact strength of the printed sample due to better bonding from a wider raster structure, while an increased LT leads to deterioration of mechanical properties. If the ratio d_nozzle/LT is greater than 2, a good tensile performance is obtained. An improved T_nozzle leads to a sufficient flow of material, contributing to the performance of the printed device. The considerations brought forward result in a deeper understanding of the FFF process and offer guidance about parameter selection. The optimal d_nozzle/v_print/LT/T_nozzle combination is 0.5 mm/120 mm s⁻¹/0.15 mm/230 °C.

Vinyl-functionalized graphene oxide (VGO) was used as a reactive compatibilizer to prepare poly(lactic acid)/polybutylene adipate-co-terephthalate (PLA/PBAT) blends. The linear rheological and scanning electron microscopy results confirmed that the VGO nanosheets were quite efficient in compatibilizing PLA/PBAT blends. The size of the PBAT dispersed phase was remarkably decreased in the presence of VGO nanosheets. Moreover, the VGO nanosheets exhibited strong nucleating effects on the crystallization process of PLA. The crystallinity of PLA component in the compatibilized blend with various VGO nanosheets was higher than 40%, upon the cooling rate of 20 °C/min. The prepared PLA/PBAT pellets were applied to 3D printing, using a self-developed screw-based 3D printer. The results showed that all the prepared PLA/PBAT blend pellets can be 3D printed successfully. The notched Izod impact test results showed that, in the presence of VGO, an increase of at least 142% in impact strength was achieved for PLA/PBAT blend. This could be attributed to the compatibilizing effect of the VGO nanosheets. Thus, this work provides a novel way to prepare tough PLA-based materials for 3D printing.