Study on Optimization of Extrusion Process for Polypropylene/Ultra High Molecular Weight Polyethylene as Fused Filament Fabrication (FFF) 3D Printer Material

Authors

  • Shahrul Izwani Christopher Universiti Tun Hussein Onn Malaysia
  • Khairu Kamarudin Universiti Tun Hussein Onn Malaysia
  • Fakrul Nur Aiman Universiti Tun Hussein Onn Malaysia
  • Mohd Khairuddin M.S Universiti Tun Hussein Onn Malaysia
  • Siti Nur Hanifah Zamri Universiti Tun Hussein Onn Malaysia

Keywords:

Polypropylene (PP), Fused Filament Fabrication (FFF), Ultra High Molecular Weight Polyethylene (UHMWPE), Extrusion, Mechanical Testing, Design of Experiment (DOE)

Abstract

This study focused on the development and optimization of polypropylene (PP) and ultra-high molecular weight polyethylene (UHMWPE) composite filaments for fused filament fabrication (FFF) 3D printing. An 80:20 PP/UHMWPE blend was selected to enhance mechanical performance while maintaining printability. Filament extrusion parameters were optimized using a design of experiments (DOE) approach, identifying an optimal temperature of 180 °C and extrusion speed of 110 mm/s. The optimized filament exhibited good dimensional stability with an average diameter of 2.78 mm. Mechanical testing showed that the PP/UHMWPE composite achieved a 19.3% increase in ultimate tensile strength compared to pure PP, along with improvements in stiffness and toughness. These results demonstrate the strong potential of PP/UHMWPE composite filaments for FFF applications requiring improved strength and reliability.

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Published

19-05-2026

Issue

Vol. 7 No. 1 (2026): PEAT

Section

Mechanical, Manufacturing, and Process Technology

How to Cite

Christopher, S. I., Khairu Kamarudin, Fakrul Nur Aiman, Mohd Khairuddin M.S, & Siti Nur Hanifah Zamri. (2026). Study on Optimization of Extrusion Process for Polypropylene/Ultra High Molecular Weight Polyethylene as Fused Filament Fabrication (FFF) 3D Printer Material. Progress in Engineering Application and Technology, 7(1), 490-497. https://publisher.uthm.edu.my/periodicals/index.php/peat/article/view/22880