This article presents a distinctive method of developing hydrophobic filaments for fused filament fabrication (FFF) of a hydrophobic mesh for oil-water separation. In this method, a modified solvent casting method is used to develop hydrophobic filaments for mesh fabrication. The fabrication process is achieved by integrating concentrations of hexadecyltrimethoxysilane (HDTMS) and polytetrafluoroethylene (PTFE) into a polylactic acid (PLA) slurry. In order to check the filament property, the filaments are characterized using water contact angle (WCA) measurements, scanning electron microscopy (SEM), Fourier transform infrared spectroscopy (FTIR), and thermal gravimetric analysis (TGA). The observations revealed that incorporating HDTMS and PTFE into PLA significantly enhances the filament’s hydrophobic properties by altering their microstructure. An optimal water contact angle of 125.76° is achieved with 2 g PLA + 0.2 mL HDTMS + 1 mL PTFE. Further, the SEM analysis showed that adding HDTMS and PTFE improves the surface properties by reducing voids, thereby enhancing the hydrophobicity. Furthermore, the addition of HDTMS and PTFE also improves the thermal and mechanical properties of the filaments. The current filament is expected to function as an oil-water separation mesh, which will be used in both commercial and domestic devices.
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