Nylon 12 composite optimization: Investigating influence of ceramic functional fillers on FFF 3D printing performance and rheological properties

Abstract Fused Filament Fabrication (FFF) is a promising 3D printing technology for industrial and technological applications due to its cost‐effective ability to fabricate large, complex objects from thermoplastics. Nylon 12, a versatile thermoplastic, is widely used for functional prototyping and has significant potential for end‐user applications. Our research focuses on enhancing the mechanical and thermal properties of Nylon 12 by developing composites with ceramic fillers such as zinc oxide (ZnO) and alumina (Al 2 O 3 ). This is achieved by melt mixing the fillers into the Nylon 12 polymer matrix and preparing filaments using a filament extruder. The optimal concentration of these fillers was determined by analyzing tensile strength of the polymer composites, while DSC was employed for thermal analysis. Additionally, rheological studies were conducted to assess the impact of the fillers on the viscoelastic properties and flow characteristics of Nylon 12. The Carreau‐Yasuda model was employed to study the complex viscosity of the materials. Our findings indicate that the addition of functional fillers enhances the shear thinning behavior of Nylon 12, improving material flow through the printer nozzle. This optimization leads to 3D printed structures with minimal dimensional inaccuracies, ensuring high‐quality prints suitable for commercial applications. Highlights Different functional fillers reinforced Nylon 12 composites‐based filaments for FDM 3D printing applications are manufactured. Different wt.% of functional fillers are added into Nylon 12 polymer matrix via melt mixing, and their filaments are prepared by filament extruder. Rheological studies of polymer composites were conducted to examine the influence of functional fillers in flow characteristics of polymer. The presence of functional fillers enhanced shear thinning behavior of polymer and develops maximum printable viscosity for extrusion‐based 3D printing.