Influence of Process Parameters in Material Extrusion on Product Properties Using the Example of the Electrical Resistivity of Conductive Polymer Composites

Additive manufacturing of components using the material extrusion (MEX) of thermoplastics enables the integration of multiple materials into a single part. This can include functional structures, such as electrically conductive ones. The resulting functional structure properties depend on the process parameters along the entire manufacturing chain. The aim of this investigation is to determine the influence of process parameters in filament production and additive manufacturing on resistivity. Filament is produced from a commercially available composite of polylactide (PLA) with carbon nanotubes (CNT) and carbon black (CB), while the temperature profile and screw speed were varied. MEX specimens were produced using a full-factorial variation in extrusion temperature, layer height and deposition speed from the most and least conductive in-house-produced filament and the commercially available filament from the same composite. The results show that the temperature profile during filament production influences the resistivity. The commercially available filament has a lower conductivity than the in-house-produced filament, even though the starting feedstock is the same. The process parameters during filament production are the main factors influencing the resistivity of an additively manufactured structure. The MEX process parameters have a minimal influence on the resistivity of the used PLA/CNT/CB composite.

Microwave-Assisted Sintering to Rapidly Construct a Segregated Structure in Low-Melt-Viscosity Poly(Lactic Acid) for Electromagnetic Interference Shielding

Formation of a segregated structure in conductive polymer composites is one of the most effective strategies for achieving good electrical conductivity and electromagnetic interference (EMI) shielding performance. Nevertheless, for low-melt-viscosity poly(lactic acid) (PLA), intense molecular motion occurs at the molding temperature, which is detrimental to the fixation of the conductive networks. In this study, a novel molding technique assisted by microwave heating was proposed to construct a segregated structure in a PLA/carbon nanotube (CNT) composite. The coating layer of CNTs acted as the microwave absorber and caused intense localized heating of PLA surfaces upon microwave irradiation. The surface temperature of the PLA granule was precisely regulated by adjusting the coated CNT content, microwave power, and irradiation time. Thus, the coated granules were softened and fused at an optimal sintering zone, which effectively hindered the excessive migration of CNT strips into the interior of PLA phases, and a majority retained the original CNT network in the molded composite. Meanwhile, benefiting from microwave sintering, sufficient chain diffusion and entanglement occurred in the interfacial regions, enhancing the adhesion strength among the neighboring PLA phases. The prepared PLA/CNT composite with only 5.0 wt % CNTs exhibited a high electrical conductivity of 16.3 S/m and an excellent EMI shielding effectiveness (EMI SE) of 36.7 dB at a frequency of 10.0 GHz. The results indicate that microwave-assisted sintering might be a promising alternative for constructing a segregated structure in low-melt-viscosity polymers.

Improved mechanical and electromagnetic interference shielding performance of segregated UHMWPE/CNTs via microwave-assisted sintering

Constructing the segregated networks is an efficient strategy to simultaneously achieve the high electrical conductivity and electromagnetic interference (EMI) shielding performance in conductive polymer composites (CPCs). Herein, an advanced molding technique based on microwave (MW)-assisted sintering was proposed to prepare the segregated ultrahigh molecular weight polyethylene/carbon nanotube (UHMWPE/CNT) composites. Scanning electron microscopy and optical microscopy images indicated that CNTs enriched on the surfaces of UHMWPE granules through ball milling, and the clear and complete conductive networks were observed in UHMWPE/CNT composites in the following MW sintering process, revealing that a perfect segregated structure was successfully constructed. The segregated UHMWPE/CNT composites exhibited an excellent electrical conductivity and EMI shielding performance of 49.3 S/m and 50 dB, respectively, along with a low percolation threshold of 0.10 vol%. Meanwhile, benefiting from the volumetric heating, an ideal mechanical property was also obtained in prepared composite by MW sintering. Compared with the conventional molding method, MW-assisted sintering shows its unique advantages, including better structural construction, shorter processing time, and lower energy consumption, which provides an efficient and environment-friendly method to fabricate CPCs with superior conductive and EMI shielding performance.

Novel definition of the synergistic effect between carbon nanotubes and carbon black for electrical conductivity

Anisotropic ternary composites comprising poly(methy-methacrylate) (PMMA), carbon black (CB), and carbon nanotubes (CNTs) were extruded using a capillary rheometer and the electrical conductivities of the composites were measured and presented in a detailed contour plot covering a large range of filler fractions (up to 30 vol% CNTs, 20 vol% CB). A recent generic conductivity model for ternary composites was successfully validated using the conductivity measurements. When analyzing the conductivity measurements using four traditional definitions of 'synergy' between two conductive fillers, no clear synergetic effect was observed between CB and CNT. Also, when all the conductivity data for ternary CNT/CB composites from the existing literature was carefully gathered and analyzed, the number of confirmed occurrences of strong and convincing CNT/CB synergies was surprisingly low. Finally, a novel definition of synergy based on the physical aspect, in particular, its maximum, the 'synergasm', was defined in order to obtain a more precise instrument for revealing regions of potential synergy.

Preparation and 3D-printing of highly conductive polylactic acid/carbon nanotube nanocomposites via local enrichment strategy

A novel local enrichment strategy was adopted to fabricate the highly conductive carbon nanotube/polylactic acid 3D-printed parts.