Effects of filament extrusion temperature and 3D printing parameters on the structure and mechanical properties of poly(butylene adipate‐co‐terephthalate)/poly (lactic acid) blends

Abstract

Poly(butylene adipate‐co‐terephthalate) (PBAT) is a biodegradable polymer derived from fossil‐based raw materials. Combined with poly(lactic acid) (PLA), a major material used in 3D printing, PBAT provides mechanical properties that are particularly attractive for applications requiring flexible 3D‐printed objects. However, blends with high PBAT content in fused filament fabrication (FFF) are currently not well‐documented, and optimal printing parameters remain unclear for advancing this field. This study aims to address this gap by first exploring the extrusion of filaments at different temperatures, followed by analyzing the printing conditions for PBAT/PLA blends to enhance their spectrum of applications. Using a commercial blend, Ecovio® (86 mol% PBAT), this paper demonstrates the feasibility of employing high PBAT content in the additive manufacturing process. Printing parameters such as nozzle temperature and speed were assessed based on the visual quality and mechanical properties of the specimens. The results indicate that extruding at 120°C yields smoother filaments with adequate diameter for FFF applications. Regarding 3D‐printing analysis, variations in parameters did not significantly impact elongation at break. However, increasing the nozzle temperature from 180 to 210°C and the printing speed from 50 to 80 mm/s resulted in a 29% increase in tensile strength and a 77% increase in the modulus of elasticity of the 3D‐printed specimens which is attributed to better interlayer adhesion. Therefore, high PBAT content blends can improve the performance of 3D‐printed materials, and parameters must be optimized to exploit their effectiveness fully across various industrial uses.Highlights Extrusion temperature variations minimally affect PLA/PBAT thermal properties. Higher nozzle temperature and speed significantly improve mechanical properties. Optimal printing conditions for high PBAT blends enable flexible materials. PBAT blends show potential for enhanced 3D printing performance in all sectors.