Three-Dimensional Printing of Shape Memory Liquid Crystalline Thermoplastic Elastomeric Composites Using Fused Filament Fabrication

Liquid crystalline elastomers (LCEs) are stimuli-responsive materials utilised in shape memory applications. The processability of these materials via advanced manufacturing is being paid increasing attention to advance their volume production on an industrial scale. Fused filament fabrication (FFF) is an extrusion-based additive manufacturing (AM) technique that offers the potential to address this. The critical challenge, however, is the rheological characteristics of LCEs that need to be tuned to achieve a facile processability through the extrusion-based method. In this work, new filaments of liquid crystalline thermoplastic elastomer (LCTPE) and its composites with lignin were made by the ternary system of LCE, thermoplastic polyurethane (TPU), and lignin. The results showed that TPU improves the melt flow index of the LCTPE system to approximately 10.01 g/10 min, while adding lignin further enhances the value of this index for the composites up to 21.82 g/10 min. The microstructural analysis indicated that the effective distribution of lignin and reduced domain size of the LCEs in the ternary blend contribute to the enhanced flowability of this filament through 3D printing. Samples of 3D-printed LCTPE and LCTPE/lignin composites maintained their shape memory characteristics via thermomechanical activation. Full shape recovery of the new LCTPE matrix and its composites with lignin was achieved in 39 s and 32 s at 130 °C, followed by 28 s and 24 s at 160 °C, respectively. The successful fabrication of LCTPE and LCTPE/lignin composite samples through 3D printing demonstrates a potential procedure for processing these shape memory materials using the FFF technique, and lignin offers a sustainable and cost-effective material solution that enhances the properties of this composite material.