Environmental Durability of Bio-Based and Synthetic Thermoplastic Composites in Large-Format Additive Manufacturing

This research investigates the durability of large-format 3D-printed thermoplastic composite material systems under environmental exposure conditions of moisture and freeze-thaw. Durability was evaluated for two bio-based composite material systems, namely wood-fiber-reinforced semi-crystalline polylactic acid (WF/PLA) and wood-fiber-reinforced amorphous polylactic acid (WF/aPLA), and one conventionally used synthetic material system, namely short-carbon-fiber-reinforced acrylonitrile butadiene styrene (CF/ABS). The moisture absorption, coefficient of moisture expansion, and reduction of relevant mechanical properties-flexural strength and flexural modulus-after accelerated exposure were experimentally characterized. The results showed that the large-format 3D-printed parts made from bio-based thermoplastic polymer composites, compared to conventional polymer composites, were more susceptible to moisture and freeze-thaw exposure, with higher moisture absorption and greater reductions in mechanical properties.