Influence of environmental humidity during filament storage on the structural and mechanical properties of material extrusion 3D-printed poly(lactic acid) parts

Material extrusion (MEX) is one of the most widely used additive manufacturing techniques these days. This study investigates how the properties of MEX 3D-printed objects depend on the relative humidity (RH) conditions in which filaments are stored before and during the manufacturing process. Poly(lactic acid) (PLA) filament was drawn directly from a humidity-controlled chamber into the MEX 3D printer’s nozzle. For each set of samples, the filaments were conditioned under different RH conditions, ranging from 10% to 90%. The macrostructure of the fabricated products was characterized using computed tomography, revealing increased porosity at higher RH values (from 0.84% to 4.42%). The increased porosity at higher storage RH is attributed to under-extrusion and volatile entrapment due to excess moisture. With growing storage RH, the melt flow rate of PLA also gradually increased, indicating a plasticizing effect of humidity on the biopolymer. Gel permeation chromatography and differential scanning calorimetry analyses were conducted to determine whether hydrolytic chain scission took place when PLA was processed in the presence of excessive moisture. Neither measurement indicated any considerable alteration in molecular integrity and crystalline structure as a function of storage RH. Mechanical tests, however, revealed a reduced load-bearing capacity of the manufactured PLA specimens. Flexural strength decreased from 103.0 to 99.6 MPa, and the impact strength dropped from 18.2 to 16.2 kJ/m2, which is ascribed to the increasing size of pores inside the specimens with increasing storage RH. These findings should be taken into account when designing and processing PLA products by MEX-based additive manufacturing.