Manufacturing of polymer/metal composites by fused deposition modeling process with polyethylene

Abstract

ABSTRACTIn this study, production of metal/polymer composites using polyethylene as the matrix with various contents of metal powder was investigated. Fused deposition modeling (FDM) process is one of the most popular and conventional additive manufacturing methods to produce three‐dimensional (3D) specimens from computer‐aided design data with complex geometry and lower prices in comparison with the alternative methods. Given the advantages of this process, it seems inevitable for the development of new materials. Utilizing semicrystalline plastics impose challenges for producing parts due to printing issues such as distortion and warpage. In this experimental work, a compounding production line was implemented to produce composite filaments with 25, 50, and 75 wt % of copper powder suitable for the FDM process. After dealing with printing issues, flexural, electrical conductivity, and bulk density tests were done. The micrographs of the specimens were examined via scanning electron microscopy to reveal the distribution of the copper particles. It is believed that the metal/polymer filament could be used to print new 3D parts. The material could be utilized in electromagnetic structures for some specific applications, such as shielding, with new properties. Also, by solving printing problems for a semicrystalline polymer, it can be encouraging to examine printing process for other rarely used thermoplastics. © 2019 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2020, 137, 48717.