Mechanical, Thermal, and Microstructural Characterization of FDM-Printed PLA/Obsidian Composites

FDM-printed polylactic acid (PLA) composites containing 5 and 10 wt% obsidian powder sourced from the Kars region of Eastern Anatolia (Turkey) were produced via twin-screw masterbatch extrusion and subsequent single-screw filament dilution. Mechanical (tensile, three-point flexure, notched Charpy impact, Shore D), physical (density), thermal (simultaneous TGA/DSC) and microstructural (macroscopic fractography and SEM at 100×–1000×) characterizations were performed on FDM-printed specimens. Young’s modulus rose monotonically by +9.0% at 5 wt% and +18.2% at 10 wt%, while ultimate tensile strength decreased by 12.4% and 17.3%, respectively. The flexural modulus increased by +15.2% at 5 wt% and plateaued at 10 wt% (+16.7%), whereas the flexural strength decreased by only 3.5% at 10 wt%, indicating that flexure-mode loading is markedly more tolerant of obsidian filler than axial tension. Shore D hardness rose by +2.11 points from 0 to 5 wt% with saturation thereafter. TGA showed a dual thermal effect: T5 and T10 dropped by 5–6 °C from 5 to 10 wt%, while the main decomposition rate decreased by ~46% and the decomposition interval widened from 9.7 to 23.5 °C, indicating a barrier/heat-shielding effect of dispersed silicate particles. SEM revealed a continuous ductile → transitional → brittle progression with increasing obsidian content; extended interfacial debonding lines at 10 wt% identified weak unmodified filler/matrix coupling as the principal performance-ceiling factor. Density measurements indicated a ~3–6% residual void fraction consistent with the inter-bead voids observed by SEM. To the authors’ knowledge, this is the first systematic study of obsidian as a reinforcing filler in PLA; the 5 wt% composition is identified as a strong candidate for esthetic, flexure-dominant, and low-load structural applications.