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.

Electrical discharge coating (EDC) process has been used to prepare a corrosion and wear resistant super-hydrophobic coating on the steel substrate. The coating process has been carried out by using three types of green compact tool electrodes (WS ₂ /Cu, MoS ₂ /Cu, and hBN/Cu). In these tool electrodes, powder mixing ratios (40:60, 50:50, 60:40) are varied, and their effect on coating characteristics (surface morphology, wettability, corrosion, and wear behaviour) has been studied. In this investigation, the morphology and chemical state of coating has been observed by using a scanning electron microscopy (SEM) and X-ray photoemission spectroscopy (XPS). SEM images of the applied coating show a porous and hierarchical structure. This hierarchical structure helps in raising the contact angle (CA) to 165.6° (super-hydrophobic state). The XPS analysis reveals that the deposition of solid lubricants takes place with their negligible disintegration into non-lubricating compounds. In addition, the prepared coating exhibits excellent resistance to wear and corrosion.

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.