Optimization of silicon carbide (SiC) nanopowder content in acrylonitrile styrene acrylate (ASA) polymeric matrix for outdoor applications in MEX additive manufacturing

The use of 3D printed components often requires materials with good resistance to weather conditions, which is usually a weak point of thermoplastics. Acrylonitrile styrene acrylate (ASA) is a thermoplastic capable of withstanding extreme environmental conditions. Thus, its investigation is of great importance, especially when it comes to being processed by additive manufacturing (AM). Herein, novel ceramic nanocomposites loaded with silicon carbide (SiC) in five (5) different filler quantities (2.0–10.0 wt%) were prepared and characterized, aiming to be used in lightweight automotive interior and exterior parts, customized aerospace, electrical and electronic housing, or tooling and fixtures. Matrix-filler mixtures were extruded into filaments to 3D print a series of specimens. The samples underwent tests for their performance during thermal, rheological, (thermo-) mechanical, structural, and morphological examinations. 6.0 wt% was distinguished overall for its performance over ASA pure, showing improvement in tensile strength (15.1%), modulus of elasticity (14.1%), flexural strength (16.8%), and modulus of elasticity (19.1%). 8.0 wt% had the highest tensile toughness (13.8%) and flexural toughness (10.6%). Porosity was reduced by the addition of the SiC filler (10.0 wt% loading improved porosity by 36.5%). In total, the ASA/ SiC nanocomposites have great potential to be utilized for outdoor applications requiring 3D printed components with reinforced mechanical performance.