Abstract

The demand for the development of sustainable manufacturing processes is enhanced by the necessity to optimize polymer composites, particularly in the context of fused deposition modeling (FDM). This research aims to enhance sustainable polymer composites to improve the surface metamorphosis during FDM processes. Various eco-friendly polymer matrices were integrated with novel composite reinforcements to evaluate their impact on surface quality, structural integrity, and the performance of FDM-printed components. Key surface features, including roughness (Ra), texture, and function, were quantified through both experimental and computational methods. The optimized composites led to a significant reduction in surface roughness, with Ra values improving by up to 45% compared to standard filaments. In addition, tensile strength was increased by 30% and flexural strength by 20% relative to unmodified polymer composites. Optimization strategies, guided by green chemistry principles and materials science, successfully enhanced surface finishes and functional properties, aligning with sustainability goals. The results demonstrate that optimized sustainable polymer composites can significantly improve the quality and performance of FDM prints, supporting more efficient and environmentally friendly manufacturing practices. This study contributes to advancing materials and processes in line with sustainability principles and surface engineering.