Morphological, Rheological and Electromagnetic Properties of Nanocarbon/Poly(lactic) Acid for 3D Printing: Solution Blending vs. Melt Mixing

Synthesis and Electrical Percolation of Highly Amorphous Polyvinyl Alcohol/Reduced Graphene Oxide Nanocomposite

Polyvinyl alcohol is the most commercially water-soluble biodegradable polymer, and it is in use for a wide range of applications. It shows good compatibility with most inorganic/organic fillers, and enhanced composites may be prepared without the need to introduce coupling agents and interfacial modifiers. The patented high amorphous polyvinyl alcohol (HAVOH), commercialized with the trade name G-Polymer, can be easily dispersed in water and melt processed. HAVOH is particularly suitable for extrusion and can be used as a matrix to disperse nanocomposites with different properties. In this work, the optimization of the synthesis and characterization of HAVOH/reduced graphene oxide (rGO) nanocomposite obtained by the solution blending process of HAVOH and Graphene Oxide (GO) water solutions and 'in situ' reduction of GO is studied. The produced nanocomposite presents a low percolation threshold (~1.7 wt%) and high electrical conductivity (up to 11 S/m) due to the uniform dispersion in the polymer matrix as a result of the solution blending process and the good reduction level of GO. In consideration of HAVOH processability, the conductivity obtained by using rGO as filler, and the low percolation threshold, the nanocomposite presented here is a good candidate for the 3D printing of a conductive structure.

Applications, fluid mechanics, and colloidal science of carbon-nanotube-based 3D printable inks

Additive manufacturing, also known as 3D printing (3DP), is a novel and developing technology, which has a wide range of industrial and scientific applications. This technology has continuously progressed over the past several decades, with improvement in productivity, resolution of the printed features, achievement of more and more complex shapes and topographies, scalability of the printed components and devices, and discovery of new printing materials with multi-functional capabilities. Among these newly developed printing materials, carbon-nanotubes (CNT) based inks, with their remarkable mechanical, electrical, and thermal properties, have emerged as an extremely attractive option. Various formulae of CNT-based ink have been developed, including CNT-nano-particle inks, CNT-polymer inks, and CNT-based non-nanocomposite inks (i.e., CNT ink that is not in a form where CNT particles are suspended in a polymer matrix). Various types of sensors as well as soft and smart electronic devices with a multitude of applications have been fabricated with CNT-based inks by employing different 3DP methods including syringe printing (SP), aerosol-jet printing (AJP), fused deposition modeling (FDM), and stereolithography (SLA). Despite such progress, there is inadequate literature on the various fluid mechanics and colloidal science aspects associated with the printability and property-tunability of nanoparticulate inks, specifically CNT-based inks. This review article, therefore, will focus on the formulation, dispersion, and the associated fluid mechanics and the colloidal science of 3D printable CNT-based inks. This article will first focus on the different examples where 3DP has been employed for printing CNT-based inks for a multitude of applications. Following that, we shall highlight the various key fluid mechanics and colloidal science issues that are central and vital to printing with such inks. Finally, the article will point out the open existing challenges and scope of future work on this topic.

A solution-processable and highly flexible conductor of a fluoroelastomer FKM and carbon nanotubes with tuned electrical conductivity and mechanical performance

The use of fluoroelastomer nanocomposites for flexible electronics is increasing due to their high deformability and recoverability. Often, a high amount of conductive nanofillers and crosslinking agents is required to improve their mechanical performance, which unfavorably affects the electrical percolation threshold and conductivity due to dispersion issues. Herein, we developed a unique solution mixing (SM) technique by a fine-tuned formulation to obtain well-dispersed carbon nanotubes (CNTs) in fluoroelastomer FKM for both low and high CNT concentrations (0.2 phr and 3 phr). Effective nano-network formation was confirmed by transmission electron microscopy (TEM) and oscillatory shear rheological tests. Compared to the melt mixing (MM) process, the stretchability of neat FKM improves to 503% in the SM process versus 430% in the MM process. The electrical conductivity of the SM samples percolates at significantly lower filler concentrations (i.e., 0.35 phr in SM vs. 0.45 phr in MM) with a maximum value of 7 × 10^-1 S cm^-1 for 3 phr. Overall, the 2 phr CNT/FKM nanocomposite fabricated by SM exceeds those of carbon-based FKM conductors reported in the literature. The enhanced electrical and mechanical properties include an electrical conductivity of 3 × 10^-1 S cm^-1, a strain-to-failure of 300%, and a tensile strength at break of 12 MPa. This process is a promising approach for fabricating fluoroelastomer nanocomposites of a mechanically robust and stable stretchable conductor for various wearable electronic devices.

Biodegradable Poly(Lactic Acid) Nanocomposites for Fused Deposition Modeling 3D Printing

3D printing by fused deposition modelling (FDM) enables rapid prototyping and fabrication of parts with complex geometries. Unfortunately, most materials suitable for FDM 3D printing are non-degradable, petroleum-based polymers. The current ecological crisis caused by plastic waste has produced great interest in biodegradable materials for many applications, including 3D printing. Poly(lactic acid) (PLA), in particular, has been extensively investigated for FDM applications. However, most biodegradable polymers, including PLA, have insufficient mechanical properties for many applications. One approach to overcoming this challenge is to introduce additives that enhance the mechanical properties of PLA while maintaining FDM 3D printability. This review focuses on PLA-based nanocomposites with cellulose, metal-based nanoparticles, continuous fibers, carbon-based nanoparticles, or other additives. These additives impact both the physical properties and printability of the resulting nanocomposites. We also detail the optimal conditions for using these materials in FDM 3D printing. These approaches demonstrate the promise of developing nanocomposites that are both biodegradable and mechanically robust.

Percolation Conduction of Carbon Nanocomposites

Carbon nanocomposites present a new class of nanomaterials in which conducting carbon nanoparticles are a small additive to a non-conducting matrix. A typical example of such composites is a polymer matrix doped with carbon nanotubes (CNT). Due to a high aspect ratio of CNTs, inserting rather low quantity of nanotubes (on the level of 0.01%) results in the percolation transition, which causes the enhancement in the conductivity of the material by 10-12 orders of magnitude. Another type of nanocarbon composite is a film produced as a result of reduction of graphene oxide (GO). Such a film is consisted of GO fragments whose conductivity is determined by the degree of reduction. A distinctive peculiarity of both types of nanocomposites relates to the dependence of the conductivity of those materials on the applied voltage. Such a behavior is caused by a non-ideal contact between neighboring carbon nanoparticles incorporated into the composite. The resistance of such a contact depends sharply on the electrical field strength and therefore on the distance between neighboring nanoparticles. Experiments demonstrating non-linear, non-Ohmic behavior of both above-mentioned types of carbon nanocomposites are considered in the present article. There has been a model description presented of such a behavior based on the quasi-classical approach to the problem of electron tunneling through the barrier formed by the electric field. The calculation results correspond qualitatively to the available experimental data.

Essential Nanostructure Parameters to Govern Reinforcement and Functionality of Poly(lactic) Acid Nanocomposites with Graphene and Carbon Nanotubes for 3D Printing Application

Poly(lactic) acid nanocomposites filled with graphene nanoplatelets (GNPs) and multiwall carbon nanotubes (MWCNTs) are studied, varying the filler size, shape, and content within 1.5-12 wt.%. The effects of the intrinsic characteristics of nanofillers and structural organization of nanocomposites on mechanical, electrical, thermal, and electromagnetic properties enhancement are investigated. Three essential rheological parameters are identified, which determine rheology-structure-property relations in nanocomposites: the degree of dispersion, percolation threshold, and interfacial interactions. Above the percolation threshold, depending on the degree of dispersion, three structural organizations are observed in nanocomposites: homogeneous network (MWCNTs), segregated network (MWCNTs), and aggregated structure (GNPs). The rheological and structural parameters depend strongly on the type, size, shape, specific surface area, and functionalization of the fillers. Consequently, the homogeneous and segregated network structures resulted in a significant enhancement of tensile mechanical properties and a very low electrical percolation threshold, in contrast to the aggregated structure. The high filler density in the polymer and the low number of graphite walls in MWCNTs are found to be determinant for the remarkable shielding efficiency (close to 100%) of nanocomposites. Moreover, the 2D shaped GNPs predominantly enhance the thermal conductivity compared to the 1D shaped MWCNTs. The proposed essential structural parameters may be successfully used for the design of polymer nanocomposites with enhanced multifunctional properties for 3D printing applications.

Graphene/Carbon Nanotube Hybrid Nanocomposites: Effect of Compression Molding and Fused Filament Fabrication on Properties

The present work reports on the production and characterization of acrylonitrile butadiene styrene (ABS) hybrid nanocomposite filaments incorporating graphene nanoplatelets (GNPs) and carbon nanotubes (CNTs) suitable for fused filament fabrication (FFF). At first, nanocomposites with a total nanofiller content of GNP and/or CNT of 6 wt.% and a GNP/CNT relative percentage ratio of 0, 10, 30, 50, 70, and 100 were produced by melt compounding and compression molding. Their mechanical, electrical resistivity, and electromagnetic interference shielding effectiveness (EMI SE) properties were evaluated. The hybrid nanocomposites showed a linear increase in modulus and decrease in strength as a function of GNP content; on the other hand, the addition of CNT in hybrid nanocomposites determined a positive increase in electrical conductivity, but a potentially critical decrease of melt flow index. Due to the favorable compromise between processability and enhancement of performance (i.e., mechanical and electrical properties), the hybrid composition of 50:50 GNP/CNT was selected as the most suitable for the filament production of 6 wt.% carbonaceous nanocomposites. EMI SE of ABS-filled single CNT and hybrid GNP/CNT nanofillers obtained from compression molding reached the requirement for applications (higher than -20 dB), while slightly lower EMI SE values (in the range -12/-16 dB) were obtained for FFF parts dependent on the building conditions.

Effect of Porosity and Crystallinity on 3D Printed PLA Properties

Additive manufacturing (AM) is a promising technology for the rapid tooling and fabrication of complex geometry components. Among all AM techniques, fused filament fabrication (FFF) is the most widely used technique for polymers. However, the consistency and properties control of the FFF product remains a challenging issue. This study aims to investigate physical changes during the 3D printing of polylactic acid (PLA). The correlations between the porosity, crystallinity and mechanical properties of the printed parts were studied. Moreover, the effects of the build-platform temperature were investigated. The experimental results confirmed the anisotropy of printed objects due to the occurrence of orientation phenomena during the filament deposition and the formation both of ordered and disordered crystalline forms (α and δ, respectively). A heat treatment post-3D printing was proposed as an effective method to improve mechanical properties by optimizing the crystallinity (transforming the δ form into the α one) and overcoming the anisotropy of the 3D printed object.

Nanocarbon/Poly(Lactic) Acid for 3D Printing: Effect of Fillers Content on Electromagnetic and Thermal Properties

Electromagnetic and thermal properties of a non-conventional polymer nanocomposite based on thermoplastic Polylactic acid (PLA, Ingeo™) filled, in different weight percentage, with multi-walled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), as well as a mixture of both fillers (MWCNTs/GNPs), are analyzed. The combination of notable electrical, thermal, and electromagnetic (EM) properties of the carbon fillers, in concentrations above the percolation threshold, together with the good processability of the PLA matrix gives rise to innovative filaments for 3D printing. In particular, the shielding efficiency (SE) in the frequency range 26–37 GHz of samples increases from 0.20 dB of unfilled PLA up to 13.4 dB for composites containing MWCNTs and GNPs, corresponding to 4% and 95% of SE, respectively. The thermal conductivity of the PLA loaded with 12 wt % of GNPs is 263% higher than that of the unfilled polymer, whereas an improvement of about 99% and 190% is detected for the PLA matrix loaded with MWCNTs and both fillers, respectively. The EM and thermal characterization is combined with a morphological investigation allowing us to correlate the dispersion states of the fillers within the polymer matrix with the observed EM and thermal properties. The EM and thermal characteristics exhibited by the nanocomposites make them suitable for packaging applications of electronic devices with electromagnetic interference (EMI) shielding and thermal dissipation features.