Abstract
With recent developments in additive manufacturing (AM), new possibilities for fabricating smart structures have emerged. Recently, single-process fused-filament fabrication (FFF) sensors for dynamic mechanical quantities have been presented. Sensors measuring dynamic mechanical quantities, like strain, force, and acceleration, typically require conductive filaments with a relatively high electrical resistivity. For fully embedded sensors in single-process FFF dynamic structures, the connecting electrical wires also need to be printed. In contrast to the sensors, the connecting electrical wires have to have a relatively low resistivity, which is limited by the availability of highly conductive FFF materials and FFF process conditions. This study looks at the Electrifi filament for applications in printed electrical conductors. The effect of the printing-process parameters on the electrical performance is thoroughly investigated (six parameters, >40 parameter values, >200 conductive samples) to find the highest conductivity of the printed conductors. In addition, conductor embedding and post-printing heating of the conductive material are researched. The experimental results helped us to understand the mechanisms of the conductive network’s formation and its degradation. With the insight gained, the optimal printing strategy resulted in a resistivity that was approx. 40% lower than the nominal value of the filament. With a new insight into the electrical behavior of the conductive material, process optimizations and new design strategies can be implemented for the single-process FFF of functional smart structures.
Highlights
IntroductionCombining multi-material fused-filament fabrication (FFF) and functional composite materials enables the fabrication of an object with embedded functional elements (sensorics [1], actuation [2], heating [3], and energy storage [4], etc.) in a single-step printing process.FFF 3D printing is based on the deposition of the melted filament feedstock onto the build surface.Sequentially deposited traces of melted material in horizontal layers form the fused printed structure.Filament FFF materials must exhibit a melting point in the working temperature range of the FFFFilaments can be manufactured with the addition of various filler particles with functional properties that enable the fabrication of functional structures.Conductivity is achieved with various conductive fillers, based on conductive carbon nanomaterials and metals that are mixed with a thermoplastic matrix to ensure the printability of the composite material [5]
Combining multi-material fused-filament fabrication (FFF) and functional composite materials enables the fabrication of an object with embedded functional elements in a single-step printing process.FFF 3D printing is based on the deposition of the melted filament feedstock onto the build surface.Sequentially deposited traces of melted material in horizontal layers form the fused printed structure.Filament FFF materials must exhibit a melting point in the working temperature range of the FFFFilaments can be manufactured with the addition of various filler particles with functional properties that enable the fabrication of functional structures.Conductivity is achieved with various conductive fillers, based on conductive carbon nanomaterials and metals that are mixed with a thermoplastic matrix to ensure the printability of the composite material [5]
The focus of this study is the influence on the resistivity of the following process parameters: layer height h, trace spacing d, printing speed v, trace width w via the extrusion rate, nozzle temperature Tnozzle, and bed temperature Tbed
Summary
Combining multi-material fused-filament fabrication (FFF) and functional composite materials enables the fabrication of an object with embedded functional elements (sensorics [1], actuation [2], heating [3], and energy storage [4], etc.) in a single-step printing process.FFF 3D printing is based on the deposition of the melted filament feedstock onto the build surface.Sequentially deposited traces of melted material in horizontal layers form the fused printed structure.Filament FFF materials must exhibit a melting point in the working temperature range of the FFFFilaments can be manufactured with the addition of various filler particles with functional properties that enable the fabrication of functional structures.Conductivity is achieved with various conductive fillers, based on conductive carbon nanomaterials and metals that are mixed with a thermoplastic matrix to ensure the printability of the composite material [5]. Combining multi-material fused-filament fabrication (FFF) and functional composite materials enables the fabrication of an object with embedded functional elements (sensorics [1], actuation [2], heating [3], and energy storage [4], etc.) in a single-step printing process. FFF 3D printing is based on the deposition of the melted filament feedstock onto the build surface. Deposited traces of melted material in horizontal layers form the fused printed structure. Filaments can be manufactured with the addition of various filler particles with functional properties that enable the fabrication of functional structures. The most conductive filaments found were based on metal fillers (e.g., two-dimensional silver powder [6], nickel and tin alloy [7], and silver-coated copper nanowires [8])
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