The use of 3D printing technology for manufacturing new products based on sustainable materials enables one to take advantage of secondary raw materials derived from recycling. This work investigates the structural performances of 3D printing composite filaments based on polylactic acid (PLA), as a matrix, reinforced by recycled carbon fiber (rCF). Carbon fibers were recovered from industrial scraps by a patented thermal process and used to produce thermoplastic composite filaments for additive manufacturing without any additional treatment and additives. The influence of the recovered carbon fiber (rCF) content on the thermal properties, mechanical properties and microstructure of the composites was studied in the range of 3–20 wt%. The recorded TGA curves exhibited a one-stage weight loss within the temperature range 290–380 °C for all samples and the residual rCF content was in good agreement with the theoretical fiber loading. The Young modulus of the extruded filaments strongly increased below a critical content (5 wt%), while at higher content the improvement was reduced. An increase in the storage modulus of 54% compared to neat PLA 3D printed sample resulted in a printed specimen with a higher rCF content. SEM images highlighted a strong rCF prevailing alignment in the direction of the extrusion flow, creating almost unidirectional reinforcement inside the filament. These findings suggest that homogeneous composite filaments reinforced with well-dispersed recycled CF without additional chemical modification and additives are suitable materials for additive manufacturing. The effect of rCF topological distribution within the material on the mechanical performances has been discussed, highlighting that the isolated fibers could efficiently transfer loads with respect to the percolated 3D network and have been correlated with the microstructure.

This study presents a novel approach to the development of high-performance supercapacitors through 3D printing technology. We synthesized a composite material consisting of silver-doped reduced graphene oxide (rGO) and dodecylbenzenesulfonic acid (DBSA)-doped polyaniline (PANI), which was further blended with polylactic acid (PLA) for additive manufacturing. The composite was extruded into filaments and printed into circular disc electrodes using fused deposition modeling (FDM). These electrodes were assembled into symmetric supercapacitor devices with a solid-state electrolyte. Electrochemical characterization, including cyclic voltammetry (CV) and galvanostatic charge–discharge (GCD) tests, demonstrated considerable mass-specific capacitance values of 136.2 F/g and 133 F/g at 20 mV/s and 1 A/g, respectively. The devices showed excellent stability, retaining 91% of their initial capacitance after 5000 cycles. The incorporation of silver nanoparticles enhanced the conductivity of rGO, while PANI-DBSA improved electrochemical stability and performance. This study highlights the potential of combining advanced materials with 3D printing to optimize energy storage devices, offering a significant advancement over traditional manufacturing methods.

The production of spherical powders has recently registered a boost due to the need to fabricate new printing materials for Additive Manufacturing applications, from polymers and resins to metals and ceramics. Among these materials, stainless steels powders play a leading role, since they are widely used in industry and everyday life; indeed, micron-sized spherical stainless steel powders have specific characteristics and are considered as one of the best candidates for Additive Manufacturing systems and for application in a wide range of sectors. In this paper, stainless steel 316 L powders were used to explore and identify the best process parameters of a thermal plasma process able to produce spherical powders for Additive Manufacturing applications. X-ray Diffraction, Scanning Electron Microscopy, Particle Size Distribution and Flowability analysis were performed to characterize reagents and products. Powders with a high circularity (>0.8) and improved flowability (<30 s/50 g) were successfully obtained. The collected results were compared with data available from the literature to identify the potential use of the spherical produced powders.

Alumina is the most widely used oxide ceramic, and its applications are widespread in engineering and in biomedical fields. Its spheroidization was performed by a prototypal direct current (DC) thermal plasma, which was designed and installed at ENEA, investigating surface morphology, particle size distribution, crystallinity, spheroidization, and reactivity. Features such as morphology and porosity significantly influence the flowability of the powder on the printer bed and, consequently, the density of the printed parts. It has been reported that spherical powder shape is highly recommended in additive manufacturing (AM) due to its superior flowability compared to other shapes whose interaction between powder particles results in poor flowability. In this paper, the spheroidization process of alumina powders using two different DC plasma powers and two kinds of secondary gas is reported. The average value of the circularity of the powders, after plasma treatment, has always been greater than or equal to 0.8 with the degree of the spheroidization over 90% at high power. The best process parameters of the thermal plasma were properly selected to produce spherical powders suitable for AM applications, and powders with high circularity were successfully obtained. Forming, debinding, and sintering tests were performed to verify the processability and the densification of produced powders, with good results in terms of density (97%).

Carbon fiber-reinforced composites (CFRCs) have attracted considerable attention in recent years due to their excellent properties, enabling their use across various sectors. However, their application at high temperatures is limited by the fibers’ lack of oxidation resistance. This study demonstrates a significant advancement in enhancing the oxidation stability performance of carbon fiber-reinforced composites (CFRCs) by developing a silicon carbide (SiC) coating through the ceramization of carbon fibers using silicon (Si) powder. For the first time, this method was applied to recycled carbon fibers from CF thermoplastic composites. The key findings include the successful formation of a uniform SiC coating, with coating thickness increasing with process duration and decreasing at higher temperatures. The treated fibers exhibited substantially improved oxidation resistance, maintaining structural stability above 700 °C—markedly better than that of their uncoated counterparts. Thermogravimetric analysis confirmed that oxidation resistance varied depending on the CF/Si ratio, highlighting this parameter’s critical role. Overall, this study offers a viable pathway to enhance the thermal durability of recycled carbon fibers for high-temperature applications.

This work presents the design and fabrication of microstructured hydrophobic surfaces via fused filament fabrication (FFF) 3D printing with polylactic acid (PLA). Three geometric patterns—triangular-based prisms (TG), truncated pyramids (TP), and truncated ellipsoidal cones (CET)—were developed to modify the surface wettability. Morphological analysis revealed that the printer resolution limits the accurate reproduction of sharp CAD-defined features. Despite this, TG structures exhibited superhydrophobic behavior evaluated through static water contact angles (WCAs), reaching up to 164° along the structured direction and so representing a 100% increase relative to flat PLA surfaces (WCA = 82°). To improve print fidelity, TP and CET geometries with enlarged features were introduced, resulting in contact angles up to 128°, corresponding to a 56% increase in hydrophobicity. The truncated shapes enable the fabrication of the smallest features achievable via the FFF technique, while maintaining good resolution and obtaining higher contact angles. In addition, surface functionalization with fluoropolymer-coated SiO₂ nanoparticles, confirmed by SEM and Raman spectroscopy, led to a further slight enhancement in wettability up to 18% on the structured surfaces. These findings highlight the potential of FFF-based microstructuring, combined with surface treatments, for tailoring the wetting properties of 3D-printed polymeric parts with promising applications in self-cleaning, de-icing, and anti-wetting surfaces.