New composites containing a natural filler made of diatom shells (frustules), permitting the modification of polylactide matrix, were produced by Fused Deposition Modelling (3D printing) and were thoroughly examined. Two mesh fractions of the filler were used, one of <40 µm and the other of 40−63 µm, in order to check the effect of the filler particle size on the composite properties. The composites obtained contained diatom shells in the concentrations from 0% to 5% wt. (0−27.5% vol.) and were subjected to rheological analysis. The composites obtained as filaments of 1.75 mm in diameter were used for 3D printing. The printed samples were characterized as to hydrophilic–hydrophobic, thermal and mechanical properties. The functional parameters of the printed objects, e.g., mechanical characteristics, stability on contact with water and water contact angle, were measured. The results revealed differences in the processing behavior of the samples as well as the effect of secondary granulation of the filler on the parameters of the printing and mechanical properties of the composites.

For the first time, the three-dimensional (3D) internal structure of naturally produced Didymosphenia geminata frustules were nondestructively visualized at sub-100 nm resolution. The well-optimized hierarchical structures of these natural organisms provide insight that is needed to design novel, environmentally friendly functional materials. Diatoms, which are widely distributed in freshwater, seawater and wet soils, are well known for their intricate, siliceous cell walls called ‘frustules’. Each type of diatom has a specific morphology with various pores, ribs, minute spines, marginal ridges and elevations. In this paper, the visualization is performed using nondestructive nano X-ray computed tomography (nano-XCT). Arbitrary cross-sections through the frustules, which can be extracted from the nano-XCT 3D data set for each direction, are validated via the destructive focused ion beam (FIB) cross-sectioning of regions of interest (ROIs) and subsequent observation by scanning electron microscopy (SEM). These 3D data are essential for understanding the functionality and potential applications of diatom cells.

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