Low-cost desktop-sized fused deposition modeling (FDM) printers have been widely embraced by small to large-scale institutions and individuals. To further enhance their utility and increase the range of materials that they can process, this work proposes a low-cost solution that adapts to low-cost desktop-sized extruders and enables them to fabricate filaments comprising a wide range of nonorganic reinforcing particles. This solution will fill a gap in the field, as low-cost fabrication techniques for reinforced filaments have been lacking. In the proposed solution, particles are heated and deposited on thermoplastic pellets to form a coating. Coated pellets are subsequently extruded using a low-cost desktop single-screw extruder. The effectiveness of the process is demonstrated by fabricating polylactic acid (PLA) filaments reinforced with two types of reinforcements, namely, dune sand and silicon carbide. Filaments' stiffness and strength were measured, and their microstructure along their lateral and longitudinal directions were investigated. Improvements in tensile strength (up to 8%) and stiffness (up to 4.5%) were observed, but at low reinforcement levels (less than 2 wt%). Results showed that the proposed process could be used to fabricate filaments with multiple types of particles. The produced filaments were successfully used to fabricate 3D parts using a commercial desktop FDM printer.
Keywords: 3D printing; FDM; composite filaments; filament extrusion; reinforced filaments.