Melt crystallization of PLA/Talc in fused filament fabrication

The fused filament fabrication (FFF) process is characterized by fast local temperature decrease. Such characteristic usually leads to lower crystallinity degree in final printed parts when semi-crystalline polymers are used. By melt-compounding poly(lactic acid) (PLA) with its nucleating agent Talc, filaments of PLA/Talc composite were produced and used in FFF. Through investigations in static/dynamic mechanical and thermal properties, and morphology, the influence of Talc on the PLA based composite in FFF are revealed: after melt compounding with Talc, PLA matrix can crystallize considerably during fast cooling in FFF; as a consequence, final parts exhibited higher degree of crystallinity than the case of neat PLA; furthermore, melt crystallization process releases heat, promoting coalescence between adjacent layers, and ultimately contributes to higher parts stiffness and better mechanical integrity. This paper presents a first example in which in-situ melt crystallization is recovered for semi-crystalline polymers during FFF via composition modification. With this example, an increase in crystallinity from 3.6% to 12% can lead to 15% increase in flexural modulus for FFF printed parts. Research results also provide insights in material property reinforcement, heat treatment on finished parts, and explorations in other semi-crystalline materials in FFF.