Advances In 3D Printing Technology Research Articles

Multilevel Diffractive Lenses: Recent Advances and Applications

Multilevel diffractive lenses (MDLs) has undergone considerable advancements, marked by their exceptional efficiency and diverse focusing capabilities, resulting in their widespread use in optical systems. In recent times, MDLs have consistently been juxtaposed with metalenses, which have experienced swift progress over the last decade. Concurrently, MDLs have continued to evolve, propelled by their distinct advantages, such as cost-effective production and adaptability for mass manufacturing. This article explores the evolution and foundational concepts of MDLs, highlighting the advantages of their circular symmetry in enhancing simulation and optimization efficiency. Furthermore, we present several innovative fabrication methods for MDLs that capitalize on the latest advancements in 3D printing technology. We also show the practical applications and potential future developments of MDLs.

Avascular Necrosis of the Talus: Diagnosis, Treatment, and Modern Reconstructive Options

Talar avascular necrosis (AVN) is a devastating condition that frequently follows type III and IV talar neck fractures. As 60% of the talus is covered by hyaline cartilage, its vascular supply is limited and prone to trauma, which may eventually lead to AVN development. Early detection of AVN (Hawkins sign, MRI) is crucial, as it may prevent the development of the irreversible stages III and IV of AVN. Alertness is advised regarding non-obvious conditions that may cause this complication (sub chondroplasty, systemic lupus erythematosus, diabetes mellitus). Although, in stages I–II, AVN may be treated with non-surgical procedures (ESWT therapy, non-weight bearing) or joint-sparing techniques (core drilling, bone marrow aspirate injections), stages III–IV require more advanced procedures, such as joint-sacrificing procedures (hindfoot arthrodesis/ankle arthrodesis), or replacement surgery, including total talar replacement (TTR) or combined total ankle replacement (TAR). The advancement of 3D-printing technology and increased access to implant manufacturing are contributing to a rise in the production rates of third-generation total talar prostheses. As a result, there is a growing frequency of alloplasty procedures and combined total ankle replacement (TAR) surgeries. By performing TTR as opposed to deses, the operator avoids (i) delayed union, (ii) a shortening of the limb, (iii) a lack of mobility, and (iv) the stiffening of adjacent joints, which are the main disadvantages of joint-sacrificing procedures. Simultaneously, TTR and combined TAR offer (i) a brief period of weight-bearing restriction, (ii) quick pain relief, and (iii) preservation of the length of the limb. Here, we summarize the most up-to-date knowledge regarding AVN diagnosis and treatment, with a special focus on the role of TTR.

A 3D printed serrated contact structure triboelectric nanogenerator for swimming training safety monitoring

The wearable electronic devices integrated with 3D printing have attracted much attention, but the continuous power supply demand and limited application scenarios have limited their development. Here, we propose a 3D printed serrated contact structure triboelectric nanogenerator (S-TENG) designed for mechanical energy harvesting and swimming training safety monitoring. Leveraging the advancements in 3D printing technology, we created a flexible, lightweight sensor integrated with polytetrafluoroethylene (PTFE) and polyethylene terephthalate (PET) films on a serrated substrate. This configuration enhances the contact surface area, leading to a significant improvement in energy harvesting efficiency compared to flat structures. Specifically, the serrated structure resulted in a 64 %, 63 %, and 47 % increase in open-circuit voltage (Voc), short-circuit current (Isc), and transferred charge (Qsc), respectively, owing to the contact area and unique surface functional structure. The S-TENG device exhibits excellent performance under various bending angles, with Voc, Isc, and Qsc reaching up to 98.04 V, 4.35 μA, and 38.51 nC at 90° bending. Additionally, the S-TENG maintains stable output in different humidity environments due to its fully encapsulated design, ensuring reliable operation in aquatic settings. The S-TENG can accurately measure elbow swing amplitude and frequency, providing valuable real-time data for athletes and coaches. The S-TENG's ability to detect irregular movements and potential drowning incidents underscores its promise in enhancing swimmer safety. This research demonstrates the S-TENG's utility in both energy harvesting and motion monitoring, paving the way for advanced wearable sports sensors in various athletic disciplines.

From Design to Clinical Translation: Unraveling Orthotist Perspectives on 3D Printed Accommodative Insoles

ABSTRACT Introduction Custom accommodative insoles have become the gold standard for managing plantar pressures and reducing ulceration risk in persons with diabetes. With advances in 3D-printing technologies, methods of fabricating 3D-printed accommodative insoles have emerged. Clinician feedback is imperative to developing a 3D-printed accommodative insole that meets clinical needs and is more effective than the current standard of care (SoC). Objective The aim of this study was to inform the development of 3D-printed accommodative insoles by gaining clinician perspective on insole requirements and application of the digital workflow for seamless translation into the clinical setting. Study Design This article is a qualitative study. Materials and Methods Four focus groups with a total of 16 orthotists were held, prompting discussions on the current SoC accommodative insole and other 3D-printed insoles we have developed. Sessions were recorded and transcribed, and main themes were derived from transcriptions. Results Review and analysis of the transcripts resulted in four main themes: 1) reimbursement, 2) durability, 3) effectiveness, and 4) workflow application in clinic. Conclusions The responses showed areas to focus improvements on the 3D-printed insole design and ways to ease the transition into a clinical setting. Clinician support is crucial in the adoption of a new device to clinical practice. Their feedback is essential to ensuring the item meets the clinical needs and the workflow is not disruptive to the clinical setting. Clinical Relevance Understanding clinician perspective on current SoC disadvantages and shortcomings, areas for improvement in the 3D-printed insole fabrication, and what is feasible in clinic appointments will help inform insole design and aid in translating new 3D-printing technology to clinical care for improved patient outcomes.

Current applications of three-dimensional (3D) printing in pediatric dentistry: a literature review.

Advancements in 3D printing technology are providing a new direction in pediatric dentistry by offering innovative solutions to traditional challenges. The remarkable expansion of 3D printing necessitates a comprehensive examination of its status and applications in the dental field, particularly in the pediatric dentistry. This review provides a comprehensive exploration of the applications of 3D printing in pediatric dental practices by drawing from a systematic search across databases, including PubMed/MEDLINE, Scopus, Web of Science, Scielo and the Cochrane Library. The search strategy employed a combination of keywords: "Digital dentistry and 3D printing", "3D printing technology in dentistry", "3D printing in pediatric dentistry" and "3D printing in pediatric dental procedures". The review encompasses a wide array of studies, including original research, cross-sectional analyses, case reports and reviews. A detailed overview is presented in regard to the use of 3D printing for master and educational models, space maintainers, prosthetic restorations, surgical guide, splint design and fracture treatment, fluoride application, autogenous dental transplantation, anterior teeth restoration, and pediatric endodontics and regenerative treatments. This review shows that 3D printing improves clinical outcomes through personalized and precise treatment options and enhances dental students' educational landscape. Areas lacking extensive research were also identified, which warrent further investigation to optimize the integration of 3D printing in pediatric dentistry. By mapping out the current landscape and future directions, the aim of this paper is to support pediatric dentists in recognizing the broad implications of 3D printing for improving patient care and advancing dental education.

3D-printed titanium scaffolds loaded with gelatin hydrogel containing strontium-doped silver nanoparticles promote osteoblast differentiation and antibacterial activity for bone tissue engineering.

Bone tissue engineering offers a promising alternative to stimulate the regeneration of damaged tissue, overcoming the limitations of conventional autografts and allografts. Recently, titanium alloy (Ti) implants have garnered significant attention for treating critical-sized bone defects, especially with the advancement of 3D printing technology. Although Ti alloys have impressive versatility, their lack of cellular adhesion, osteogenic and antibacterial properties are significant factors that contribute to their failure. Hence, to overcome these obstacles, this study aimed to incorporate osteoinductive and antibacterial cue-loaded hydrogels into 3D-printed Ti (3D-Ti) scaffolds. 3D-Ti scaffolds were synthesized using the direct metal laser sintering method and loaded with a gelatin (Gel) hydrogel containing strontium-doped silver nanoparticles (Sr-Ag NPs). Compared with Ag NPs, Sr-doped Ag NPs increased the expression of Runx2 mRNA, which is a key bone transcription factor. We subjected the bioactive 3D-hybrid scaffolds (3D-Ti/Gel/Sr-Ag NPs) to physicochemical and material characterization, followed by cytocompatibility and osteogenic evaluation. The microporous and macroporous topographies of the scaffolds with Sr-Ag NPs showed increased Runx2 expression and matrix mineralization, with potent antibacterial properties. Therefore, the 3D-Ti scaffolds incorporated with Sr-Ag NP-loaded Gel hydrogels favored osteoblast differentiation and antibacterial activity, indicating their potential for orthopedic applications.

Data-driven prediction of strain fields in auxetic structures and non-contact validation with mechanoluminescence for structural health monitoring

Recent advancements in 3D printing technology have significantly enhanced the potential of auxetic structures, which are notable for their negative Poisson’s ratio, particularly in applications such as sensor technology and structural health monitoring. Central to the performance of these structures is the accurate estimation of the effective strain parameter, a critical metric for assessing structural integrity. However, as structural complexity increases, estimating this parameter becomes increasingly challenging. The fabrication and real-world validation of these structures are equally important challenges. This paper introduces two key innovations for the practical application of auxetic structures. First, we present a multi-kernel hierarchical deep neural network that leverages finite element simulation data to accurately predict effective strain fields in complex auxetic configurations. This model architecture not only reduces the number of parameters requiring training but also enhances feature learning and generalization capabilities, achieving over 90% accuracy in predicting strain fields. Second, we validate these predictions using a 3D-printed specimen embedded with mechanoluminescent (ML) particles. This approach enables direct, non-contact visualization of strain in real-time, offering high spatial and temporal resolution. The alignment observed between predicted and observed strain concentration areas demonstrates the efficacy of integrating ML technology into auxetic designs. This integration significantly improves the reliability and diagnostic capabilities of advanced structural systems.

Replicating Mg scaffold via 3D printing sacrificial template

The fabrication of hierarchical and porous structures holds significant promise in biomedical science, aerospace, and related fields. Despite advancements in 3D printing technology that have enhanced the capability of complex porous structures, its application in metal fabrication remains challenging. In this paper, we introduce a method involving a 3D printed sacrificial template, created by the material extrusion process, for magnesium (Mg) infiltration. This method facilitates the production of porous Mg scaffolds, with the templates subsequently being water-leached. The morphology, shrinkage rate, compressive strength, and types of lattices of templates were observed and assessed to determine their viability. Further, comprehensive compression tests and cell adhesion experiments were conducted on the Mg scaffolds to evaluate their performance. The results suggest that the templates must possess adequate strength and continuous flow channels for successful Mg infiltration. The scaffolds experienced an average of about 30 % shrinkage from the initial design to the final structure. The porous Mg scaffolds exhibit enhanced compressive strength (47.48 ± 0.84 MPa) at lower porosity (0.52) and demonstrate satisfactory biocompatibility. This research highlights the efficacy and low cost of the template replication method in generating mechanically superior porous Mg scaffolds with customized pore sizes and structures. In future research, this method also holds promise for applications involving newly developed alloys.

The Effects of Shear Stress on the Micromechanical Properties of 3D Printable Biopolymer Nanocomposites Using a Custom‐Designed Extrusion‐Based 3D Printer

Current advancements in 3D printing technology have the potential to facilitate the production of scaffolds and implants for various biomedical applications, including bone repair and regeneration. 3D printed patient‐specific bone‐inspired nanocomposite grafts might be a viable alternative to current bone repair treatment methods if they provide appropriate anatomic structure, biocompatibility, and adequate mechanical properties. In the current work, a 3D printable nanocomposite biomaterial ink with bone cell biocompatibility (in vitro) is printed while adjusting shear stress during extrusion using a custom‐designed 3D printer to investigate the shear stress effect on the mechanical properties of the 3D printed nanocomposite. Tensile test results, as well as polarized light microscopy and differential scanning calorimetry analyses, reveal that increasing the applied shear stress from 3.5 to 14 kPa during extrusion‐based 3D printing in a custom‐built 3D printer, increased the strength, tensile modulus, and toughness of printed nanocomposite filaments by about three‐fold. This improvement is attributed to increased crystallinity in the thermoset biopolymer matrix due to the higher shear stress and the nano‐confinement effect. This implies that greater shear during layer‐by‐layer extrusion‐based 3D printing might be employed to create more robust mechanically competent 3D printed nanocomposite bone grafts.

Advancement of 3D printing technology for the development of a training model in US-guided vesicoamniotic shunting for early LUTO therapy.

Prenatal lower urinary tract obstruction (LUTO) is a rare and challenging condition with potential severe morbidity and mortality. Prenatal shunting methods, specifically vesicoamniotic shunting (VAS) and fetal cystoscopy, aim to manage this condition. However, comprehensive education and training are hindered by the rarity of LUTO. To address this gap, we present a low-cost 3D-printed ultrasound training model for VAS in LUTO fetuses. The aim of the study was to evaluate ultrasound and haptic fidelity of the model. Ultrasound images of three LUTO fetuses at 12-14 weeks were utilized to create detailed 3D-printed models. Fusion360TM software generated stereo-lithography files, and the Formlabs Form3® printer, using Flexible 80A resin, produced the models. A simulation box mimicking uterine conditions and fetal anatomy was developed for testing. Ultrasound assessments determined model accuracy, and expert evaluations gauged fidelity for VAS placement. The 3D-printed model accurately replicated LUTO fetal anatomy, demonstrating structural integrity and realistic sonographic and haptic feedback during 20 punctures. Macroscopic visualization confirmed the model's durability and authenticity. This innovative 3D-printed model addresses the scarcity of LUTO cases and the lack of realistic training tools. Simulation models enhance skills, providing a controlled learning environment that bridges theoretical knowledge and clinical application, potentially improving patient outcomes. The 3D-printed training model for VAS in LUTO represents a significant advancement in surgical education, offering realistic anatomical simulation and tactile feedback. Future studies should assess its effectiveness in enhancing surgical skills and impacting patient outcomes in clinical practice.

The History and Future of Ceramic Sculpture: From Ancient Clay Figures to Modern 3D Printing

This research aims to examine the history and future of ceramic sculpture, evaluating the development of this significant art form. It observes the role and evolving face of ceramic sculpture art from ancient times to the present, discussing its potential in the future. In ancient times, people used ceramic sculptures to express their religious and mythological beliefs. Civilizations such as Ancient Egypt, Ancient Greece, and the Roman Empire reflected their beliefs and cultures through ceramic sculptures. During the Middle Ages and Renaissance periods, artisans produced ceramic sculptures to enhance the aesthetic and religious aspects of churches' interior decoration. The sculptures from these periods stood out for their traditional craftsmanship and handmade techniques. With the onset of the modern era, technological advancements have fundamentally transformed ceramic sculpture art. Artists have observed diversity and change in the artistic expressions of ceramic sculptures as they address societal, political, and environmental issues, creating new and contemporary works. The relationship between ceramic art and technology has continued to grow, especially with the recent advancements in 3D printing technology, which provide artists with greater creative freedom and allow for the creation of more complex forms and details in sculptures. While ceramic sculpture art remains an essential part of our cultural heritage, artists will continue to shape the thoughts and societal consciousness of people through ceramic sculptures in the future. As a form of art that has evolved throughout history, ceramic sculpture art will persist in representing the creativity and freedom of expression of artists, enhancing the artistic experiences of individuals with the conveniences brought about by technology.

Development and Outlook for the FDM Printed Nozzle Structure

Abstract:: The nozzle is one of the parts of a 3D printer that cannot be missed because of its widespread popularity in recent years. The nozzle's structure determines the quality of the printed product; therefore, selecting a suitable nozzle structure is crucial. With the advancement of 3D printing technology in recent years, 3D printers have progressively come under investigation. Examining the design of the nozzle, feeding mechanism, and printing platform can help to increase the quality of the prints. The design and enhancement of the nozzle structure are beneficial to the advancement of 3D printing technology since it is one of the key elements influencing print quality. Using the research methods, research content, and invention structure of the most recent representative patents on this nozzle structure, the features and operating principle of the 3D printed nozzle structure are illustrated. To classify and examine the nozzle temperature and nozzle clogging that impact the nozzles, a patent analysis of various types of 3D printing nozzle structures is carried out. Future trends in 3D printing nozzle structures are also covered. The issues caused by nozzle work can be resolved to increase product quality and precision by comparing various 3D printing nozzle structures. This will also lead to the invention of more relevant patents in the future, including those about printing numerous nozzles and high-strength metals.

Direct 3D printing aligners - past, present and future possibilities.

The aim of this paper is to introduce the general dentist to recent advances in 3D printing technology used in orthodontics. 3D printing is a highly evolving area of dentistry with continual developments. New advances now allow the in-house delivery of printed aligners. Advocates of this new technology suggest the benefits of more prescriptive and controlled tooth movement in comparison to conventional thermoformed appliances. However, there is currently limited evidence on the efficiency of this material and more research needs to be carried out to validate this new technology.

Evolution and Innovations in Pattern Making Techniques for Enhanced Garment Construction: A Comprehensive Review

Pattern-making has evolved significantly over time, combining traditional craftsmanship with technological advancements like computer-aided design software and 3D modelling. This has increased accuracy, efficiency, and productivity in garment design, allowing for greater creativity and customization. Sustainability principles have become a priority in the fashion industry, with designers using zero-waste design approaches to minimize textile waste. Digital tools have revolutionized traditional pattern-making practices, facilitating collaboration between designers and manufacturers, enhancing accuracy and precision. Virtual and augmented reality have added a new dimension to pattern-making and garment construction, allowing designers to visualize and experience their designs in a virtual environment before translating them into physical garments. Technological innovations have also led to advancements in materials and manufacturing processes, offering designers more options for innovative and eco-friendly designs. The integration of 3D printing into modern garment construction has revolutionized the fashion industry by offering designers new possibilities for creativity and efficiency. Future trends in pattern-making include virtual and augmented reality technologies for virtual fitting rooms and advances in 3D printing technology for direct garment printing.

Exploring the Impact of 3D Printing Technology on Patient-Specific Prosthodontic Rehabilitation: A Comparative Study

ABSTRACT Introduction: The rapid advancement of 3D printing technology has opened new avenues for patient-specific prosthodontic rehabilitation. This study aimed to explore the impact of 3D printing technology on prosthodontic outcomes and patient satisfaction through a comparative analysis. Materials and Methods: A total of 100 patients requiring prosthodontic rehabilitation were recruited for this study. The patients were randomly divided into two groups: the experimental group, where 3D printing technology was utilized for the fabrication of patient-specific prostheses, and the control group, where conventional fabrication techniques were employed. Various parameters were assessed, including prosthesis fit, occlusion, esthetics, and patient-reported outcomes such as comfort and satisfaction. Digital measurements and subjective evaluations were conducted to compare the outcomes between the two groups. Statistical analysis was performed using appropriate tests. Results: Preliminary findings indicated that the use of 3D printing technology in prosthodontic rehabilitation resulted in superior prosthesis fit, enhanced occlusal stability, and improved esthetics compared to conventional methods. Moreover, patients in the experimental group reported higher levels of comfort and overall satisfaction. The advantages of 3D printing technology were observed across different types of prosthodontic restorations, including crowns, bridges, and dentures. These results highlight the potential of 3D printing technology to revolutionize patient-specific prosthodontic rehabilitation. By facilitating precise fabrication, customization, and improved functional outcomes, 3D printing can enhance the overall quality of prosthodontic care. Further long-term studies are warranted to validate these findings and explore the cost-effectiveness and long-term durability of 3D-printed prostheses. Conclusion: In conclusion, this study demonstrates that the integration of 3D printing technology in patient-specific prosthodontic rehabilitation holds great promise for achieving optimal functional and esthetic outcomes. The findings contribute to advancing prosthodontic practices and provide valuable insights for clinicians and researchers seeking to incorporate this innovative technology into their treatment protocols.

Sustainable supply chain models for 3D printed houses

ABSTRACT Although steps have been taken to improve sustainable practices in the construction industry, progress to date has been slow. Advances in 3D printing technology provide a significant opportunity to reconfigure construction industry supply chains to improve its sustainability credentials. This study investigates the adoption of 3D construction printing (3DCP) as a sustainable alternative and/or to augment traditional construction industry supply chains. By analysing six 3DCP organisations and feeding six critical insights into the Business Model Navigator, this study proposes three supply chain models i.e. generative construction service, hybrid service, and emergency service. A generative supply chain model can be used as an on-demand service for customers with limited knowledge of 3DCP. The hybrid model can integrate 3DCP with a traditional construction supply chain to construct part of the building. Finally, the emergency services model can be used to rapidly construct cost-effective housing (e.g for refugees). The adoption of 3D Printing using these supply chain models in housing construction supply chains has the potential to offer considerable benefits both for construction companies and end-users, while at the same time improving sustainability, affordability and productivity.

Transforming organ transplantation and medical education advancements in 3D printing technology

A major issue in the medical field worldwide is the limited number of organ donors available for transplants. The conventional methods are constrained by issues like scarcity of donors, further harm, and limited resources. The 3D printing technology provides a hopeful remedy by allowing the quick creation of customized tissue scaffolds, fixing tissue defects with cells, and potentially printing organs and tissues. These customized implants blend with the patient's tissue and include specific material patterns and cell clusters to promote cell growth and maturation, aiding in tissue repair. This review examines the existing obstacles and progress in 3D printing for medical purposes, specifically focusing on materials and extracellular matrix fabrication, showcasing different types of biomedical materials and recent innovations.

Mechanical properties of hierarchical lattice via strain gradient homogenization approach

With the advancement of 3D printing technology, manufacturing metamaterials with extreme mechanical properties is becoming more feasible. Hierarchical lattices appear to be ideal candidates for obtaining desirable lightweight, high specific stiffness, and enhanced specific energy absorption. They can be constructed by architected substructures at multiple length scales. The interpretations of the underlying deformation mechanisms are necessary in order to manipulate with expected mechanical properties. In this paper, experiments were conducted to examine the effective mechanical behaviors of hierarchical lattice metamaterials. A strain gradient homogenization approach has been employed to correlate their morphological characteristics to the resulting material properties. The effective stiffness tensors are identified including the fourth-, fifth-, and sixth-order stiffness tensors. The higher-order inertial parameters are determined by a fitting procedure. Comparisons between direct finite element analyses and the homogenized strain gradient continua have been made for hierarchical lattice materials under static and dynamic loads. It is found that strain gradient homogenization approach can be an accurate, efficient and reliable way of predicting the mechanical behaviors of hierarchical lattice. A systematic analysis of geometrical parameters was conducted to uncover the underlying mechanisms responsible for the enhancement of effective properties. This work offers a novel approach for designing the mechanical properties of hierarchical metamaterials through precise control of secondary structure types and distributions.

Transforming P & O Care with 3D Printing-More than Meets the Eye.

Many within the prosthetics and orthotics (P&O) industry are embracing 3D printing technology to produce better devices more efficiently, cost-effectively and to improve patient outcomes. 3D printing is here to stay, but how much will it transform P&O practices? This paper explores the state-of 3D printing technology as it applies to P&O and aims to highlight important considerations for bringing 3D printing into mainstream practice. The paper draws from recent published literature, as well as experiences stemming from ongoing efforts focused on implementing digital workflows and 3D printing into P&O care. The paper examines the topic from the technological, research, economics, funding, and clinical perspectives. While 3D printing and digital workflows have advantages over traditional methods (i.e. ability to design more complex parts, reprinting and reproduction of parts, less labour intensive) there are also challenges limiting adoption. First, despite recent advancements in 3D printing technology, gaps still exist in terms of the materials and processes. For example, cost-effectively fabricating devices that are concurrently strong and durable, allow for colourful designs, and are thermoformable are still being developed. Cost-wise, 3D printing may currently be more viable for small, or paediatric devices. There are also limited technical standards to ensure safe and durable devices are produced, as well as a lack of evidence and information about patient outcomes and operating costs. Nevertheless, a great amount of enthusiasm and momentum exists within the industry to innovate, and with it the potential for 3D printing to one day be central to mainstream P&O care. Given the many aspects of the P&O industry, collaboration and partnerships will facilitate learning from each other to advance and realize the potential of 3D printing sooner.

Synthesis, Processing, and Characterization of CNT Filaments for Printing of High-Performance Flexible Electronics

The rapid advancement of 3D printing technology has provided opportunities for exploring novel materials, such as carbon nanotubes (CNTs), that possess significant capabilities for improving electrical devices. CNTs exhibit remarkable conductivity and mechanical characteristics within the flexible electronics domain, rendering them an up-and-coming contender for propelling advancements in this discipline. The synthesis, processing, and characterization of CNT-based filaments play a crucial role in entirely using the capabilities of these materials for applications in flexible electronics. This work presents the CNT Filaments for Printing System (CNT-FPS), a holistic approach incorporating cutting-edge CNT manufacturing, filament processing, and material characterization methodologies. The CNT-FPS material exhibits distinctive characteristics, such as precise control over diameter management, elevated levels of purity, and remarkable dispersion of CNTs inside the polymer matrix. The CNT-FPS method exhibited superior performance in eight key metrics. These metrics include filament diameter (1.15 mm), surface morphology (8.75 µm), electrical conductivity (375.62 S/cm), tensile strength (61.24 MPa), Young's Modulus (13.45 GPa), thermal stability (340.75°C), crystallinity (48.75%), and wear rate (0.009 mm³/Nm). The findings of this study demonstrate a potentially fruitful direction for advancing the field of high-performance flexible electronics. The research provides a foundation for developing electrical devices that exhibit exceptional durability, adaptability, and functionality through the strategic enhancement of CNT synthesis, processing, and characterization techniques inside the CNT-FPS framework. These devices have immense potential for diverse applications like wearable technology, healthcare, and beyond.