Applied Chemical Engineering

Optimization of sustainable polymer composites for surface metamorphosis in FDM processes

S. Raja

Center for Advanced Multidisciplinary Research and Innovation, Chennai Institute of Technology, Chennai, Tamilnadu, 600069, India

Rusho Maher Ali

Masters of Engineering in Engineering Management, Lockheed Matin Engineering Management, University of Colorado, Boulder, Colorado,80308,United States

K. Ch. Sekhar

Department of Mechanical Engineering, Lendi Institute of Engineering and Technology, Jonnada, Vizianagaram , Andhra Pradesh,535005,India

Humam Muthana Jummaah

Al-Mamoon University College, Baghdad, 10012, Iraq

Rana Hussain

College of Pharmacy, Al-Turath University, 10081, Baghdad, Iraq

Ban Safir Khalaf Al- shammari

College of Medical Technology, Department of Medical Equipment Engineering, Al-Farahidi University, Baghdad, 00965, Iraq

Zainab Nizar Jawad

Department of Biology, College of Education for Pure Sciences, University of Kerbala, Kerbala, 56001, Iraq Department of Optics Techniques, Al-Zahrawi University College, Kerbala, 56001, Iraq

Mohammed Ahmed Mustafa

Department of Biology, College of Education, University of Samarra, Samarra, 34010, Iraq

Avvaru Praveen Kumar

Department of Applied Chemistry, School of Applied Natural Science, Adama Science and Technology University, Adama,1888, Ethiopia Department of Chemistry, Graphic Era (Deemed to Be University), Dehradun, Uttarakhand, 248002, India

DOI: https://doi.org/10.59429/ace.v7i4.5531

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Abstract

The demand for the development of sustainable manufacturing processes is enhanced by the necessity to optimize polymer composites, particularly in the context of fused deposition modeling (FDM). This research aims to enhance sustainable polymer composites to improve the surface metamorphosis during FDM processes. Various eco-friendly polymer matrices were integrated with novel composite reinforcements to evaluate their impact on surface quality, structural integrity, and the performance of FDM-printed components. Key surface features, including roughness (Ra), texture, and function, were quantified through both experimental and computational methods. The optimized composites led to a significant reduction in surface roughness, with Ra values improving by up to 45% compared to standard filaments. In addition, tensile strength was increased by 30% and flexural strength by 20% relative to unmodified polymer composites. Optimization strategies, guided by green chemistry principles and materials science, successfully enhanced surface finishes and functional properties, aligning with sustainability goals. The results demonstrate that optimized sustainable polymer composites can significantly improve the quality and performance of FDM prints, supporting more efficient and environmentally friendly manufacturing practices. This study contributes to advancing materials and processes in line with sustainability principles and surface engineering.

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