Abstract
This study presents a novel approach that explores the impact of both volume fraction and particle size of biosilica on the mechanical properties, wear resistance, load-bearing capacity, and time-dependent behaviour of Polylactic acid (PLA)-biosilica hybrid nanocomposites developed through Fused Deposition Modelling (FDM), a 3-dimensional (3D) printing technique. Using sustainably extracted biosilica from agricultural waste (corncob) as a filler, this study enhances the environmental sustainability of the composite while providing a robust, durable, and eco-friendly material suitable for various applications. The optimized specimen, A3, containing 99% PLA and 1 vol.% of 20 nm biosilica, exhibited the best mechanical performance. Moreover, specimen A4, which contains 98% PLA and 2 vol.% 20 nm biosilica, demonstrated outstanding wear qualities with a specific wear rate of 0.015 mm3/Nm and a coefficient of friction (COF) of 0.22. Scanning Electron Microscopic (SEM) analysis further confirmed the dispersion and adhesion characteristics within the PLA matrix. A3 displayed a uniform dispersion of biosilica particles, enhancing load transfer and crack deflection, while A4 and A7 demonstrated filler agglomeration at higher biosilica volumes, which could create weak points under mechanical loading. Thus the optimized PLA–biosilica composite (A3) is well suited for load-bearing biomedical components such as patient-specific orthotic supports and prosthetic sockets, where moderate strength, fatigue resistance, and biocompatibility are essential. Additionally, it can be effectively used in lightweight structural and tribological components such as gears, bushings, and housings in automotive and consumer applications, where enhanced wear resistance and durability are required.
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