Technological Evaluation of Algae-Based Fillers for Polymer 3D Printing

One approach to reducing the environmental footprint of conventional polymers is to compound them with bio-based fillers. Plant-based materials have already been successfully used as polymer fillers. In this context, algae-based fillers received minor attention. Due to their unique growth efficiency and ability to capture large amounts of CO2, the use of algae-based fillers could have economic and ecologic advantages. In this work, a possible use of algae as a sustainable filler for filament materials was technologically evaluated. In practical investigations, conventional polyethylene-terephthalate-glycol (PETG) was mixed with the microalgae spirulina platensis and chlorella vulgaris and extruded to 3D printing filaments. Based on printed test specimens and material samples, the printability, mechanical, and thermal properties of the composite were determined. Filaments with a homogeneous distribution of algae particles and stable diameters up to a filler content of 30 wt.% could be produced. All filaments had good printability and adequate moisture sensitivity for higher algae contents. For 30 wt.% the tensile strength of the produced filaments decreases from 54 MPa to 24 MPa, the flexural strength decreases from 87 MPa to 69 MPa, and the material operating temperature decreases slightly from 70 degrees C to 66 degrees C. The addition of smaller amounts of algae results in minor changes regarding the overall performance. The properties of the material were comparable to those of other natural fillers such as wood, bamboo or cork. The main objective of adding bio-based materials to polymeric matrices can be achieved. Our results suggest that algae-based filaments can be produced as a more sustainable and low-cost material.