Novel 3D printable bio-based and biodegradable poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) microspheres for selective laser sintering applications

Selective laser sintering (SLS) has become the most popular additive manufacturing process due to its high accuracy, productive efficiency, and surface quality. However, currently there are still very few commercially available polymeric materials suitable for this technique. This research work focused on the fabrication and characterization of bio-based and biodegradable microspheres obtained by oil-in-water emulsion solvent evaporation, starting from a poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH) biopolymer matrix. First, the fabrication parameters were optimized to improve the morphological, thermal, and flowability properties of the synthetized microspheres. Once the best production conditions were established, the PHBH microspheres were further used to study their effective 3D printability on an SLS 3D printer using geometries varying from simple shapes to architectures with more complex internal patterns. The results of this research revealed that PHBH has promising applicability for the SLS technique. This study undertook the first step toward broadening the range of polymeric materials for this additive manufacturing technology. These findings will contribute to a greater and wider dissemination of the SLS technique in the future, as well as they will bring this manufacturing process closer to applications, such as the biomedical sector, where the use of biodegradable and biocompatible materials can add value to the final application.