High-Performance Nylon-6 Sustainable Filaments for Additive Manufacturing

This study deals with the development of Nylon-6 fused deposition modeling (FDM) filaments for additive manufacturing, which couples high mechanical performances with eco-sustainability. These filaments were extruded from recycled Nylon-6 granulates through a dedicated twin-screw extrusion line, which processes either pure Nylon-6 grains, or mixtures of such a material with minor fractions of acrylonitrile butadiene styrene (ABS) and titanium dioxide (TiO₂). The rheological and thermal properties of the investigated filaments are analyzed, including melt flow index, melting temperature, and decomposition temperature, which are of the utmost importance when avoiding the overheating and decomposition of the material. Such a study is conducted in both pre-extrusion and post-extrusion conditions. The tensile strength, the wear resistance, and the printability of the examined recycled Nylon-6 filaments are also studied by comparing the properties of such filaments with those exhibited by different nylon-based filaments for FDM that are available in the market. The given results show that the recycling of Nylon-6 through the "caprolactam" regeneration route enables the newly formed material to retain high physical and mechanical properties, such as tensile strength at yield in the interval 55.79-86.91 MPa. Referring to the basic composition of the filaments examined in the present study, this remarkably high-yield strength is accompanied by a Young modulus of 1.64 GPa, and wear resistance of 92 µm, under a 15 min/1 kg load pin-on-disk test carried at the sliding speed of 250 rpm.