Production of Thermoplastic Composite Filaments for Additive Manufacturing using Recycled Carbon Fibers

The present work reports the use of recycled carbon fibers (rCF), obtained from pyro-gasification treatment of carbon fibers reinforced polymers (CFRP), to produce a thermoplastic composite filament for additive manufacturing, in particular fused deposition modeling (FDM) process. Polylactic acid (PLA), a thermoplastic biobased and biodegradable polymer, is used as matrix for the composite filament, as it is the most common plastic used in FDM due to its good mechanical properties, stiffness, and strength. Upon production process optimization, filaments with rCF loadings of 5 and 10% wt are produced and analyzed. A particular attention is devoted to the evaluation of the production process on the carbon fibers (CFs) length and the study of the thermal and mechanical properties of the obtained composite materials.