A critical review of composite filaments for fused deposition modeling: Material properties, applications, and future directions

Abstract

This review paper provides a comprehensive analysis of recent advancements in the development and application of composite filaments for fused deposition modeling (FDM) 3D printing technology. Focusing on the integration of various materials such as nano-fillers, fibers, and bio-based polymers into polylactic acid (PLA) and other thermoplastics, this study delves into how these composites enhance mechanical, thermal and functional properties of the printed objects. We critically assess studies that investigate the impact of raster orientation, filler content, and material composition on tensile, bending, and impact strength, as well as on the thermal stability and degradation behavior of composite filaments. The review highlights key findings from the literature, including the optimization of filament formulations to achieve superior mechanical performance, improved thermal resistance, and specific functional characteristics suitable for a wide range of applications from biomedical to structural components. Moreover, this paper discusses the challenges associated with composite filament production, including material compatibility, dispersion of nano-fillers, and the need for printer hardware adjustments. Future directions for research in the field are identified, emphasizing the potential for new material combinations, sustainability considerations, and the development of filaments designed for specific industrial applications. An effective way to better meet designers’ expectations for qualified materials is composite filaments. This review focuses on how these elements can be applied to improve both product design and functionality. A guide is presented in choosing composite filaments that can meet the features expected from the designed product.