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Overcoming Challenges in 3D Printing of Polyolefins and Their Composites: A Review on Strategies for Improved Printability and Performance.

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Title: Overcoming Challenges in 3D Printing of Polyolefins and Their Composites: A Review on Strategies for Improved Printability and Performance.
Authors: Hassan, Malik1,2 (AUTHOR), McMorran, Philip1,2 (AUTHOR), Eid, Marwan1,2 (AUTHOR), Blair, Julia1,2 (AUTHOR), Mohanty, Amar K.1,2 (AUTHOR) mohanty@uoguelph.ca, Misra, Manjusri1,2 (AUTHOR) mmisra@uoguelph.ca
Source: Polymer Engineering & Science. May2026, Vol. 66 Issue 5, p3100-3141. 42p.
Subjects: Polyolefins, Three-dimensional printing, Deformations (Mechanics), Printing equipment, Mechanical behavior of materials, Cohesion
Abstract: Polyolefins such as polyethylene and polypropylene are among the most widely produced thermoplastics globally due to their low cost, chemical resistance, and favorable mechanical properties. Despite their industrial importance, these polymers pose significant challenges in additive manufacturing, particularly in extrusion‐based techniques like fused deposition modeling and fused granulate fabrication. Their semi‐crystalline nature leads to shrinkage and warpage during cooling, while their low surface energy results in poor interlayer and bed adhesion. This review provides a comprehensive overview of the molecular structure, crystallinity, and catalyst systems of polyolefins, highlighting how these factors influence printability and performance. Strategies for mitigating shrinkage and warpage are critically examined, including thermal control, polymer blending, and the use of nucleating agents and fillers. Adhesion improvement methods such as the addition of compatibilizers, surface treatments, crosslinking, and thermal processing are also discussed. This review evaluates the use of recycled polyolefins and proposes material and process modifications aimed at overcoming challenges with degradation and inconsistency. Furthermore, the role of functional fillers, including talc, calcium carbonate, biocarbon, and nanoclays, is explored in the context of enhancing mechanical strength, dimensional stability, and sustainability. Through the integration of materials science, process engineering, and sustainable design, this review offers practical insights to advance the application of polyolefins in high‐performance additive manufacturing. Highlights: Addresses shrinkage, warpage, and adhesion issues in polyolefin 3D printing.Links chemistry, crystallinity, and catalyst type to printability behavior.Compares FDM, FGF, and SLS processes for polyolefin additive manufacturing.Summarizes warpage and adhesion mitigation via material and process control.Promotes sustainability using recycled polyolefins, biocarbon, and hybrid fillers. [ABSTRACT FROM AUTHOR]
Copyright of Polymer Engineering & Science is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Overcoming Challenges in 3D Printing of Polyolefins and Their Composites: A Review on Strategies for Improved Printability and Performance.
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  Data: <searchLink fieldCode="AR" term="%22Hassan%2C+Malik%22">Hassan, Malik</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22McMorran%2C+Philip%22">McMorran, Philip</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Eid%2C+Marwan%22">Eid, Marwan</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Blair%2C+Julia%22">Blair, Julia</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Mohanty%2C+Amar+K%2E%22">Mohanty, Amar K.</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> mohanty@uoguelph.ca</i><br /><searchLink fieldCode="AR" term="%22Misra%2C+Manjusri%22">Misra, Manjusri</searchLink><relatesTo>1,2</relatesTo> (AUTHOR)<i> mmisra@uoguelph.ca</i>
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  Data: <searchLink fieldCode="JN" term="%22Polymer+Engineering+%26+Science%22">Polymer Engineering & Science</searchLink>. May2026, Vol. 66 Issue 5, p3100-3141. 42p.
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  Data: <searchLink fieldCode="DE" term="%22Polyolefins%22">Polyolefins</searchLink><br /><searchLink fieldCode="DE" term="%22Three-dimensional+printing%22">Three-dimensional printing</searchLink><br /><searchLink fieldCode="DE" term="%22Deformations+%28Mechanics%29%22">Deformations (Mechanics)</searchLink><br /><searchLink fieldCode="DE" term="%22Printing+equipment%22">Printing equipment</searchLink><br /><searchLink fieldCode="DE" term="%22Mechanical+behavior+of+materials%22">Mechanical behavior of materials</searchLink><br /><searchLink fieldCode="DE" term="%22Cohesion%22">Cohesion</searchLink>
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  Data: Polyolefins such as polyethylene and polypropylene are among the most widely produced thermoplastics globally due to their low cost, chemical resistance, and favorable mechanical properties. Despite their industrial importance, these polymers pose significant challenges in additive manufacturing, particularly in extrusion‐based techniques like fused deposition modeling and fused granulate fabrication. Their semi‐crystalline nature leads to shrinkage and warpage during cooling, while their low surface energy results in poor interlayer and bed adhesion. This review provides a comprehensive overview of the molecular structure, crystallinity, and catalyst systems of polyolefins, highlighting how these factors influence printability and performance. Strategies for mitigating shrinkage and warpage are critically examined, including thermal control, polymer blending, and the use of nucleating agents and fillers. Adhesion improvement methods such as the addition of compatibilizers, surface treatments, crosslinking, and thermal processing are also discussed. This review evaluates the use of recycled polyolefins and proposes material and process modifications aimed at overcoming challenges with degradation and inconsistency. Furthermore, the role of functional fillers, including talc, calcium carbonate, biocarbon, and nanoclays, is explored in the context of enhancing mechanical strength, dimensional stability, and sustainability. Through the integration of materials science, process engineering, and sustainable design, this review offers practical insights to advance the application of polyolefins in high‐performance additive manufacturing. Highlights: Addresses shrinkage, warpage, and adhesion issues in polyolefin 3D printing.Links chemistry, crystallinity, and catalyst type to printability behavior.Compares FDM, FGF, and SLS processes for polyolefin additive manufacturing.Summarizes warpage and adhesion mitigation via material and process control.Promotes sustainability using recycled polyolefins, biocarbon, and hybrid fillers. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Polymer Engineering & Science is the property of Wiley-Blackwell and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1002/pen.70410
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      – Code: eng
        Text: English
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        PageCount: 42
        StartPage: 3100
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      – SubjectFull: Polyolefins
        Type: general
      – SubjectFull: Three-dimensional printing
        Type: general
      – SubjectFull: Deformations (Mechanics)
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      – SubjectFull: Printing equipment
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      – SubjectFull: Mechanical behavior of materials
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      – SubjectFull: Cohesion
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    Titles:
      – TitleFull: Overcoming Challenges in 3D Printing of Polyolefins and Their Composites: A Review on Strategies for Improved Printability and Performance.
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            NameFull: Hassan, Malik
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            NameFull: McMorran, Philip
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            – D: 01
              M: 05
              Text: May2026
              Type: published
              Y: 2026
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