New 3D printed material enhances industrial sustainability

Researchers at Luleå University of Technology have developed self-lubricating polymer composites that reduce friction and wear in machine components. The results may contribute to more energy-efficient and sustainable manufacturing of industrial products and technical equipment.

By combining advanced materials with 3D printing, doctoral researcher Nayan Dhakal at Luleå University of Technology has created self-lubricating polymer composites with significantly improved wear resistance and friction performance. The material, based on the high-performance thermoplastic PEEK, has demonstrated up to 50 percent friction reduction compared to neat polymer matrix – a result that helps reduce energy losses in industrial machinery.
"The tribological evaluation shows that these 3D-printed composites perform as well as, or even better than, conventionally manufactured components in terms of friction and wear," says Nayan Dhakal, PhD candidate in Machine Elements at Luleå University of Technology.

The manufacturing method is based on Fused Filament Fabrication (FFF), a common extrusion-based 3D printing technique for thermoplastic polymers. It allows for the fast production of advanced components with minimal material waste – an important step toward more sustainable production and lower environmental impact in a circular economy system.

Designed for Demanding Environments

To enhance material performance, the researchers incorporated microscale carbon fibers and nanoscale silica particles into the PEEK matrix. These additives improved the internal structure and significantly enhanced tribological performance.

"We found that the nanoparticles strengthened the interfacial bonding between fibers and matrix, which reduced internal porosity and improved durability (service life)," says Nayan Dhakal.

Tribological investigations showed that the experimental materials not only matched but in some cases outperformed the friction performance of compression-molded components. This suggests that 3D printing may serve as a viable alternative to traditional manufacturing techniques for critical applications.

"This opens the door to decentralized, on-demand production where parts can be custom-made and fabricated on-site when needed," says Nayan Dhakal.

Nayan Dhakal, doctoral student in machine elements at Luleå University of Technology.

Environmental Impact Across the Lifecycle

Beyond improved mechanical performance, the project emphasizes sustainability from a system perspective. By reducing energy losses during operation and limiting the need for transport, the approach supports several UN Sustainable Development Goals – including SDG 9 (Industry, Innovation and Infrastructure), SDG 11 (Sustainable Cities and Communities), and SDG 12 (Responsible Consumption and Production).

"We show that it is possible to combine sustainability approach with technical advancement, which is essential for the future of manufacturing," says Nayan Dhakal.

The project is part of the EU-funded MSCA-EJD-GreenTRIBOS programme and has been carried out in collaboration between Luleå University of Technology and the University of Leeds. Nayan Dhakal recently defended his thesis for both institutions as part of a dual-award doctoral degree programme.

• Machine elements