Fabrication and Characterization of a Novel 3D-Printable Bio-Composite from Polylactic Acid (PLA) and...

To address the growing demand for sustainable materials in advanced manufacturing, the objective of this study was to develop and characterize a novel 3D-printable biocomposite using ruminant-digested corn stover (DCS) as a reinforcement for polylactic acid (PLA). The methodology involved systematically optimizing DCS particle size (80-140 mesh) and loading concentration (5-20 wt.%), followed by fabricating composite filaments via melt extrusion and 3D printing test specimens. The resulting materials were comprehensively characterized for their morphological, physical, and mechanical properties. The optimal formulation, achieved with 120-mesh particles at 15 wt.% loading, exhibited a 15.6% increase in tensile strength to 64.17 MPa and a 21.1% enhancement in flexural modulus to 4.19 GPa compared to neat PLA. In addition to the mechanical improvements, the biocomposite offers an advantageous density reduction, enabling the fabrication of lightweight structures for resource-efficient applications. Comprehensive characterization revealed effective interfacial integration and uniform fiber dispersion, validating biological preprocessing as a viable method for unlocking the reinforcement potential of this abundant biomass. While the composite exhibits characteristic trade-offs, such as reduced impact strength, the overall performance profile makes it a promising candidate for structural applications in sustainable manufacturing. This research establishes a viable pathway for agricultural waste valorization, demonstrating that biological preprocessing can convert agricultural residues into value-added engineering materials for the circular bioeconomy.