Valorization of Biochar as a Reinforcement Agent in Polyethylene Terephthalate Glycol for Additive Manufacturing: A Comprehensive Content Optimization Course

This study aimed to develop a biochar-modified polyethylene terephthalate glycol (PETG) composite for 3D printing. Biochar prepared from olive tree prunings was compounded with PETG at different loadings and then processed into filaments through a controlled extrusion process. The resultant filaments were used to print test specimens, which were characterized thoroughly by mechanical, thermal, morphological, and rheological methods. The tensile strength (17.8%), flexural strength (15.9%), impact resistance (20.9%), and thermal stability of the biochar-reinforced composites were substantially improved. Overall, the 6.0 wt.% biochar compound exhibited the highest improvement. Scanning electron microscopy and energy-dispersive X-ray spectroscopy confirmed the excellent dispersion of biochar in the PETG matrix. The results demonstrated that biochar is an effective, environmentally friendly material to use as a reinforcing agent for additive manufacturing. The PETG/biochar composites have a promising future for various industrial applications, offering sustainable alternatives with superior performance characteristics.