Optimization of Silicon Nitride Nanopowder Content in Polyamide 12 (PA12) in Extrusion-Based Additive Manufacturing

The use of polyamide-12 (PA12) thermoplastics in additive manufacturing (AM) is promising owing to their mechanical properties and printability. However, in load-bearing applications, improvements in mechanical strength and stiffness are sought after. Herein, the reinforcement efficiency of silicon nitride (Si₃N₄) nanoparticles in the PA12 matrix was explored. The filler loading varied between 2.0 wt. % and 10.0 wt. %. The nanocomposites were extruded into filament using melt compounding for subsequent material extrusion (MEX) 3D printing. PA12/Si₃N₄ nanocomposites were examined for their thermal, rheological, morphological, and structural characteristics. For mechanical characterization, flexural, tensile, microhardness, and Charpy impact data were obtained. For structural examination, porosity and dimensional deviation were assessed. Scanning electron microscopy (SEM) was used to investigate morphology and chemical composition. The results indicate that Si₃N₄ nanopowder significantly improved all mechanical properties, with a greater than 20% increase in tensile strength and elastic modulus when compared to neat PA12. The structural characteristics were also improved. These findings indicate that Si₃N₄ nanoparticles provide a viable reinforcement filler for PA12 for use in lightweight, robust structural components fabricated using MEX AM. Furthermore, it can be stated that ceramic-polymer nanocomposites further improve the applicability of PA12, where high mechanical performance is required.