“Biochar” (BC) is the solid residue recovered from the thermal cracking of biomasses in an oxygen-poor atmosphere. Recently, BC has been increasingly explored as a sustainable, inexpensive, and viable alternative to traditional carbonaceous fillers for the development of polymer-based composites. In fact, BC exhibits high thermal stability, high surface area, and electrical conductivity; moreover, its main properties can be properly tuned by controlling the conditions of the production process. Due to its intriguing characteristics, BC is currently in competition with high-performing fillers in the formulation of multi-functional polymer-based composites, inducing both high mechanical and electrical properties. Moreover, BC can be derived from a huge variety of biomass sources, including post-consumer agricultural wastes, hence providing an interesting opportunity toward a “zero waste” circular bioeconomy. This work aims at providing a comprehensive overview of the main achievements obtained by combining BC with several thermoplastic and thermosetting matrices. In particular, the effect of the introduction of BC on the overall performance of different polymer matrices will be critically reviewed, highlighting the influence of differently synthesized BC on the final performance and behavior of the resulting composites. Lastly, a comparative perspective on BC with other carbonaceous fillers will be also provided.

Biocomposites based on poly(lactic acid) (PLA) and biochar (BC) particles derived from spent ground coffee were prepared using two different processing routes, namely melt mixing and solvent casting. The formulated biocomposites were characterized through rheological, thermal, and mechanical analyses, aiming at evaluating the effects of the filler content and of the processing method on their final properties. The rheological characterization demonstrated the effectiveness of both exploited strategies in achieving a good level of filler dispersion within the matrix, notwithstanding the occurrence of a remarkable decrease of the PLA molar mass during the processing at high temperature. Nevertheless, significant alterations of the PLA rheological behavior were observed in the composites obtained by melt mixing. Differential scanning calorimetry (DSC) measurements indicated a remarkable influence of the processing method on the thermal behavior of biocomposites. More specifically, melt mixing caused the appearance of two melting peaks, though the structure of the materials remained almost amorphous; conversely, a significant increase of the crystalline phase content was observed for solvent cast biocomposites containing low amounts of filler that acted as nucleating agents. Finally, thermogravimetric analyses suggested a catalytic effect of BC particles on the degradation of PLA; its biocomposites showed decreased thermal stability as compared with the neat PLA matrix.

Fused deposition modeling (FDM) is one of the most commonly used commercial technologies of materials extrusion-based additive manufacturing (AM), used for obtaining 3D-printed parts using thermoplastic polymers. Notwithstanding the great variety of applications for FDM-printed objects, the choice of materials suitable for processing using AM technology is still limited, likely due to the lack of rapid screening procedures allowing for an efficient selection of processable polymer-based formulations. In this work, the rheological behavior of several 3D-printable, commercially available poly(lactic acid)-based filaments was accurately characterized. In particular, each step of a typical FDM process was addressed, from the melt flowability through the printing nozzle, to the interlayer adhesion in the post-deposition stage, evaluating the ability of the considered materials to fulfill the criteria for successful 3D printing using FDM technology. Furthermore, the rheological features of the investigated materials were related to their composition and microstructure. Although an exhaustive and accurate evaluation of the 3D printability of thermoplastics must also consider their thermal behavior, the methodology proposed in this work aimed to offer a useful tool for designing thermoplastic-based formulations that are able to ensure an appropriate rheological performance in obtaining 3D-printed parts with the desired geometry and final properties.

The aim of this work is the investigation of the effect of ultrasound treatment on the structural characteristics of carbon nanotubes (CNTs) and the consequent influence that the shortening induced by sonication exerts on the morphology, rheological behaviour and thermo-oxidative resistance of ultra-high molecular weight polyethylene (UHMWPE)-based nanocomposites. First, CNTs have been subjected to sonication for different time intervals and the performed spectroscopic and morphological analyses reveal that a dramatic decrease of the CNT’s original length occurs with increased sonication time. The reduction of the initial length of CNTs strongly affects the nanocomposite rheological behaviour, which progressively changes from solid-like to liquid-like as the CNT sonication time increases. The study of the thermo-oxidative behaviour of the investigated nanocomposites reveals that the CNT sonication has a detrimental effect on the thermo-oxidative stability of nanocomposites, especially for long exposure times. The worsening of the thermo-oxidative resistance of sonicated CNT-containing nanocomposites could be attributed to the lower thermal conductivity of low-aspect-ratio CNTs, which causes the increase of the local temperature at the polymer/nanofillers interphase, with the consequent acceleration of the degradative phenomena.

This paper reviews the current achievements regarding the rheological behavior of polymer-based nanocomposites containing carbon nanotubes (CNTs). These systems have been the subject of a very large number of scientific investigations in the last decades, due to the outstanding characteristics of CNTs that have allowed the formulation of nanostructured polymer-based materials with superior properties. However, the exploitation of the theoretical nanocomposite properties is strictly dependent on the complete dispersion of CNTs within the host matrix and on the consequent development of a huge interfacial region. In this context, a deep knowledge of the rheological behavior of CNT-containing systems is of fundamental importance, since the evaluation of the material’s viscoelastic properties allows the gaining of fundamental information as far as the microstructure of nanofilled polymers is concerned. More specifically, the understanding of the rheological response of polymer/CNT nanocomposites reveals important details about the characteristics of the interface and the extent of interaction between the two components, hence allowing the optimization of the final properties in the resulting nanocomposites. As the literature contains plenty of reviews concerning the rheological behavior of polymer/CNT nanocomposites, this review paper will summarize the most significant thermoplastic matrices in terms of availability and relevant industrial applications.