PLA/PBS Biocomposites for 3D FDM Manufacturing: Effect of Hemp Shive Content and Process Parameters on Printing...

This study investigates the processability-via Fused Deposition Modeling (FDM) 3D printing-and mechanical performance of biocomposites based on polylactic acid (PLA), polybutylene succinate (PBS), and their 50/50 wt% blend, each reinforced with hemp shive at 3 and 5 wt%. Blending PLA with PBS represents a straightforward and encouraging strategy to enhance both the printability and mechanical properties of the individual resins, expanding the range of their potential applications. The addition of hemp shive-a by-product of hemp processing-not only enhances the biodegradability of the composites but also improves their thermo-mechanical performance, as well as aligning with circular economy principles. The rheological characterization, performed on all the systems, evidenced that the PLA/PBS blend possesses viscoelastic properties well suited for FDM, enabling smooth extrusion through the nozzle, good shape stability after deposition, and effective interlayer adhesion. Moreover, the constrain effect of hemp shives within the polymer matrix reduced the extrudate swell, a key factor affecting the dimensional accuracy of the printed parts. Optimal processing conditions were identified at a nozzle temperature of 190 °C and a printing speed of 70 mm/s, providing a favorable compromise between print quality, final performances and production efficiency. From a mechanical perspective, the PLA/PBS blend exhibited an 8.6-fold increase in elongation at break compared to neat PLA, and its corresponding composite showed a ductility nearly three times higher than the PLA-based counterpart's. In conclusion, the findings of this study provide new insights into the interplay between material formulation, rheological behavior and printing conditions, supporting the development of sustainable, hemp-reinforced biocomposites for additive manufacturing applications.