Applied Chemical Engineering

Surface functionalization of bio-based polymers in FDM: A pathway to enhanced material performance

Raja S.

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

Maher Ali Rusho

Lockheed Martin Engineering Management, University of Colorado, Boulder, Colorado, 80308, United States

Chirag Singh

Department of product design, DLC state university of performing and visual arts,124001, India

Ali Mohamed Khalaf

Al-Mamoon University College, Baghdad, 10012, Iraq

Sajida Hussein Ismael

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

Esraa Ahmed Abdul Qader

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.v7i3.5536

---

Abstract

Such rapid advancement places FDM as a transformative technology in additive manufacturing generally, and particularly into the context of the fabrication of complex geometries using bio-based polymers. However, with such inherent limitations regarding their mechanical and thermal properties, these face significant obstacles that need innovative approaches toward improvement. Surface functionalization is now considered one of the frontline strategies in the advanced improvements of the interfacial properties and durability of biobased polymers within FDM applications and represents opportunities for enhancing material performance. This paper discusses recent advances in surface functionalization methods, including plasma treatment, grafting, and nanocoatings applied to optimize PLA, PHA, and their composites functionality. These techniques tune the surface properties at the molecular level and consequently strengthen adhesion, minimize moisture intake, and enhance thermal stability toward improved mechanical properties and longer operating time for the printed parts. Our findings indicate that incorporating functionalization of the surface in the FDM process overcomes some of the challenges of bio-based polymers and achieves the targets of sustainable manufacturing. The work underlines contemporary methods and shows both their implications and practical effects, thus opening a path to future research and industrial applications in high-performance eco-friendly materials.

---

References

[1]. Patti, A. (2024). Process–Property Correlation in Sustainable Printing Extrusion of Bio-Based Filaments. Journal of Composites Science, 8(8), 305.

[2]. Raja, S., Rajan, A. J., Kumar, V. P., Rajeswari, N., Girija, M., Modak, S., Kumar, R. V., & Mammo, W. D. (2022). Selection of Additive Manufacturing Machine Using Analytical Hierarchy Process. 2022.

[3]. Subramani, R., Kaliappan, S., Sekar, S., Patil, P. P., Usha, R., Manasa, N., & Esakkiraj, E. S. (2022). Polymer Filament Process Parameter Optimization with Mechanical Test and Morphology Analysis. 2022.

[4]. Bilal, M., Qamar, S. A., Qamar, M., Yadav, V., Taherzadeh, M. J., Lam, S. S., & Iqbal, H. M. (2024). Bioprospecting lignin biomass into environmentally friendly polymers—applied perspective to reconcile sustainable circular bioeconomy. Biomass Conversion and Biorefinery, 14(4), 4457-4483.

[5]. Raja, S., & Rajan, A. J. (2022). A Decision-Making Model for Selection of the Suitable FDM Machine Using Fuzzy TOPSIS. 2022.

[6]. Raja, S., Agrawal, A. P., Patil, P. P., Thimothy, P., Capangpangan, R. Y., Singhal, P., & Wotango, M. T. (2022). Optimization of 3D Printing Process Parameters of Polylactic Acid Filament Based on the Mechanical Test. 2022.

[7]. Pezzana, L. (2024). Towards a more sustainable world: UV-curing & 3D printing of bio-based monomers: Synthesis and characterization of bio-derived monomers for cationic and radical UV-curing.

[8]. Subramani, R., Kaliappan, S., Arul, P. V, Sekar, S., Poures, M. V. De, Patil, P. P., & Esakki, E. S. (2022). A Recent Trend on Additive Manufacturing Sustainability with Supply Chain Management Concept , Multicriteria Decision Making Techniques. 2022.

[9]. Raja, S., Logeshwaran, J., Venkatasubramanian, S., Jayalakshmi, M., Rajeswari, N., Olaiya, N. G., & Mammo, W. D. (2022). OCHSA : Designing Energy-Efficient Lifetime-Aware Leisure Degree Adaptive Routing Protocol with Optimal Cluster Head Selection for 5G Communication Network Disaster Management. 2022.

[10]. Grade, S., Zhang, X., Yang, C. H., Oduro, I., & Wang, C. (2024). Cross-linking lignin and cellulose with polymers using siloxane compounds. Frontiers in Materials, 11, 1355976.

[11]. S. Raja, A. John Rajan, "Challenges and Opportunities in Additive Manufacturing Polymer Technology: A Review Based on Optimization Perspective", Advances in Polymer Technology, vol. 2023, Article ID 8639185, 18 pages, 2023. https://doi.org/10.1155/2023/8639185

[12]. S., R., & A., J. R. (2023). Selection of Polymer Extrusion Parameters By Factorial Experimental Design – A Decision Making Model. Scientia Iranica, (), -. doi: 10.24200/sci.2023.60096.6591

[13]. Sakthi Balan, G., & Aravind Raj, S. (2024). Effect of additives on the performance of extruded polymer composites: A comprehensive review. Journal of Thermoplastic Composite Materials, 08927057241261314.

[14]. Subramani, R., Kalidass, A. K., Muneeswaran, M. D., & Lakshmipathi, B. G. (2024). Effect of fused deposition modeling process parameter in influence of mechanical property of acrylonitrile butadiene styrene polymer. Applied Chemical Engineering, 7(1).

[15]. Raja, S., AhmedMustafa, M., KamilGhadir, G., MusaadAl-Tmimi, H., KhalidAlani, Z., AliRusho, M., & Rajeswari, N. (2024). An analysis of polymer material selection and design optimization to improve Structural Integrity in 3D printed aerospace components. Applied Chemical Engineering, 7(2), 1875-1875.

[16]. Acharjee, S. A., Gogoi, B., Bharali, P., Sorhie, V., & Alemtoshi, B. W. (2024). Recent trends in the development of Polyhydroxyalkanoates (PHAs) based biocomposites by blending with different bio-based polymers. Journal of Polymer Research, 31(4), 98.

[17]. Subramani, R., Mustafa, M. A., Ghadir, G. K., Al-Tmimi, H. M., Alani, Z. K., Rusho, M. A., ... & Kumar, A. P. (2024). Exploring the use of Biodegradable Polymer Materials in Sustainable 3D Printing. Applied Chemical Engineering, 7(2), 3870-3870.

[18]. Raja, S., Mustafa, M. A., Ghadir, G. K., Al-Tmimi, H. M., Alani, Z. K., Rusho, M. A., & Rajeswari, N. (2024). Unlocking the potential of polymer 3D printed electronics: Challenges and solutions. Applied Chemical Engineering, 7(2), 3877-3877.

[19]. Righetti, G. I. C., Faedi, F., & Famulari, A. (2024). Embracing Sustainability: The World of Bio-Based Polymers in a Mini Review. Polymers, 16(7), 950.

[20]. Venkatasubramanian, S., Raja, S., Sumanth, V., Dwivedi, J. N., Sathiaparkavi, J., Modak, S., & Kejela, M. L. (2022). Fault Diagnosis Using Data Fusion with Ensemble Deep Learning Technique in IIoT. 2022.

[21]. Mohammed Ahmed Mustafa, S. Raja, Layth Abdulrasool A. L. Asadi, Nashrah Hani Jamadon, N. Rajeswari, Avvaru Praveen Kumar, "A Decision-Making Carbon Reinforced Material Selection Model for Composite Polymers in Pipeline Applications", Advances in Polymer Technology, vol. 2023, Article ID 6344193, 9 pages, 2023. https://doi.org/10.1155/2023/6344193

[22]. Yang, J., An, X., Lu, B., Cao, H., Cheng, Z., Tong, X., ... & Ni, Y. (2024). Lignin: A multi-faceted role/function in 3D printing inks. International Journal of Biological Macromolecules, 131364.

[23]. Olaiya, N. G., Maraveas, C., Salem, M. A., Raja, S., Rashedi, A., Alzahrani, A. Y., El-Bahy, Z. M., & Olaiya, F. G. (2022). Viscoelastic and Properties of Amphiphilic Chitin in Plasticised Polylactic Acid/Starch Biocomposite. Polymers, 14(11), 2268. https://doi.org/10.3390/polym14112268

[24]. Mannan, K. T., Sivaprakash, V., Raja, S., Patil, P. P., Kaliappan, S., & Socrates, S. (2022). Effect of Roselle and biochar reinforced natural fiber composites for construction applications in cryogenic environment. Materials Today: Proceedings, 69, 1361-1368.

[25]. Lecoublet, M., Ragoubi, M., Leblanc, N., & Koubaa, A. (2024). Sustainable 3D-printed cellulose-based biocomposites and bio-nano-composites: Analysis of dielectric performances. Industrial Crops and Products, 221, 119332.

[26]. Mannan, K. T., Sivaprakash, V., Raja, S., Kulandasamy, M., Patil, P. P., & Kaliappan, S. (2022). Significance of Si3N4/Lime powder addition on the mechanical properties of natural calotropis gigantea composites. Materials Today: Proceedings, 69, 1355-1360.

[27]. Wang, X., Tian, W., Ye, Y., Chen, Y., Wu, W., Jiang, S., ... & Han, X. (2024). Surface modifications towards superhydrophobic wood-based composites: Construction strategies, functionalization, and perspectives. Advances in Colloid and Interface Science, 103142.

[28]. Ram Kishore, S., Sridharan, A. P., Chadha, U., Narayanan, D., Mishra, M., Selvaraj, S. K., & Patterson, A. E. (2024). Natural fiber biocomposites via 4D printing technologies: A review of possibilities for agricultural bio-mulching and related sustainable applications. Progress in Additive Manufacturing, 9(1), 37-67.

[29]. Wang, X., Chen, G. X., Han, R., Zhou, Z., & Li, Q. (2024). Controlled synthesis of non-functionalized POSS nanoparticles with hydrophobic to hydrophilic wettability transition. Progress in Organic Coatings, 191, 108398.

[30]. Praveenkumar, V., Raja, S., Jamadon, N. H., & Yishak, S. (2023). Role of laser power and scan speed combination on the surface quality of additive manufactured nickel-based superalloy. Proceedings of the Institution of Mechanical Engineers, Part L: Journal of Materials: Design and Applications, 14644207231212566.

[31]. Sekhar, K. C., Surakasi, R., Roy, P., Rosy, P. J., Sreeja, T. K., Raja, S., & Chowdary, V. L. (2022). Mechanical Behavior of Aluminum and Graphene Nanopowder-Based Composites. 2022.

[32]. Song, X., Weng, Y., Ma, Z., Han, Y., Zhang, X., & Zhang, C. Sustainable improvement in the polylactic acid properties of 3D printing filaments: The role of bamboo fiber and epoxidized soybean oil‐branched cardanol ether compatibilizer. Polymer Composites.

[33]. Vijayakumar, P., Raja, S., Rusho, M. A., & Balaji, G. L. (2024). Investigations on microstructure, crystallographic texture evolution, residual stress and mechanical properties of additive manufactured nickel-based superalloy for aerospace applications: role of industrial ageing heat treatment. Journal of the Brazilian Society of Mechanical Sciences and Engineering, 46(6), 356.

[34]. Subramani, R., Vijayakumar, P., Rusho, M. A., Kumar, A., Shankar, K. V., & Thirugnanasambandam, A. K. (2024). Selection and Optimization of Carbon-Reinforced Polyether Ether Ketone Process Parameters in 3D Printing—A Rotating Component Application. Polymers, 16(10), 1443.

[35]. Skrodzka, M., Cieślak, A., Łabowska, M. B., Detyna, J., & Michalak, I. (2024). Bio-based additive manufacturing: an overview. Additive Manufacturing Materials and Technology, 291-316.

[36]. Prasad, A., Chakraborty, G., & Davim, J. P. (Eds.). (2024). Sustainable Bio-Based Composites: Biomedical and Engineering applications (Vol. 20). Walter de Gruyter GmbH & Co KG.