Currently, material extrusion 3D printing (ME3DP) based on fused deposition modeling (FDM) is considered a highly adaptable and efficient additive manufacturing technique to develop components with complex geometries using computer-aided design. While the 3D printing process for a number of thermoplastic materials using FDM technology has been well demonstrated, there still exists a significant challenge to develop new polymeric materials compatible with ME3DP. The present work reports the development of ME3DP compatible thermoplastic elastomeric (TPE) materials from polypropylene (PP) and styrene-(ethylene-butylene)-styrene (SEBS) block copolymers using a straightforward blending approach, which enables the creation of tailorable materials. Properties of the 3D printed TPEs were compared with traditional injection molded samples. The tensile strength and Young’s modulus of the 3D printed sample were lower than the injection molded samples. However, no significant differences could be found in the melt rheological properties at higher frequency ranges or in the dynamic mechanical behavior. The phase morphologies of the 3D printed and injection molded TPEs were correlated with their respective properties. Reinforcing carbon black was used to increase the mechanical performance of the 3D printed TPE, and the balancing of thermoplastic elastomeric and mechanical properties were achieved at a lower carbon black loading. The preferential location of carbon black in the blend phases was theoretically predicted from wetting parameters. This study was made in order to get an insight to the relationship between morphology and properties of the ME3DP compatible PP/SEBS blends.

Polyolefins are the largest class of commercially available synthetic polymers that are extensively used in a variety of applications from commodities to engineering owing to their low cost of production, good physico‐mechanical properties, light weight, good processability, and recyclability. Compared to conventional molding techniques, fused deposition modeling (FDM)‐based 3D printing is a smart manufacturing technology for thermoplastics due to its low cost, ease of production of complex geometrical parts, rapid prototyping, and scalable customization. FDM 3D printing can be an ideal manufacturing technology for polyolefins to manufacture various complex parts. However, FDM 3D‐printing of polyolefins is challenged bycritical printing problems like high warpage, dimensional inaccuracies, poor bed adhesion, and poor layer‐to‐layer adhesion. In this review, a fundamental understanding of polyolefins and their FDM 3D‐printing process is established, and the recent progress of FDM 3D printing of polyolefins is summarized. Furthermore, strategies to overcome warpage and to improve mechanical strength of the 3D‐printed polyolefins are provided. Finally, future prospectives of FDM 3D‐printing of polyolefins are critically discussed to inspire prospective research in this field. It is believed that this review article can be tremendously useful for research work related to FDM of polyolefin‐based materials.