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3D printing of magnetorheological elastomers (MREs) can potentially create versatile and complex mechanical structures with reversible stiffening properties. Several additive manufacturing (AM) methods, like direct printing and stereolithography (SLA), have been used to achieve magnetic thermoset and elastomer composite structures. For the first time, we demonstrate the use of MREs based on thermoplastic elastomers (TPE) in AM and we investigate their magnetorheological (MR) effect when used in lightweight honeycomb designs. Due to the low shore hardness of TPE, a screw extruder-based printing head is employed to print disk-shaped samples with honeycomb patterns at infill percentages varying from 15% to 50%. In order to compare the MR effect of disks with varying honeycomb infills through a compression method, we investigated the effect of different testing configurations. We observe that different permanent magnet configurations, as it has been used in literature so far, create an additional effect on the measured MR effect of the MRE samples. To eradicate this effect, a test setup with an unpaired permanent magnet configuration is proposed. MRE structures with an infill density of 20% showed, at 1% deformation range, the highest MR effect, almost four times as high as 100% infilled samples. MRE structures with an infill density between 30% and 50% showed a lower MR effect than at 20%, but were still higher than at 100%. We observe in simulations that the magnetic flux density of 100% infilled samples was higher at the edges of the samples and lower at the center. For samples with honeycomb infill, the magnetic flux density was higher at the outer rim of the samples and edges of the walls within the sample, which causes a higher MR effect. Our work demonstrates that the MR effect can be tuned by designing a MRE structure with a honeycomb infill. The honeycomb infill results in lightweight MREs with improved MR effect useful for various downstream applications that require reversible strong stiffening while remaining comparatively lightweight. [Display omitted] • Light-weight magnetorheological structures made with additive manufacturing. • Step-by-step study of magnetorheological characterization under compression mode. • Paired permanent magnets leads to overestimated magnetorheological (MR) effect. • Effect of varying honeycomb patterned infill density on MR effect was investigated. • Magnetorheological structures with lowest infill shows the highest MR effect. [ABSTRACT FROM AUTHOR]

With booming development of 5G communications and electronic devices, electromagnetic waves (EMWs) radiation pollution has aroused much concern on public, and great efforts are being made to develop the high-performance electromagnetic interference shielding (EMI SE) materials. However, inherent deficiencies of traditionally processing technology restrain the current materials to fabricate desirable architectures for SE applications. Herein, taking full advantages of 3D printing in free-construction, architected honeycombs featuring lightweight and high-efficient EMI SE are designed with polylactic acid (PLA) as matrix, and graphene nanosheets and carbon nanotubes hybrids (GNs/CNTs) as functional fillers. The optimal printed material shows a high electrical conductivity up to 110.8 S/m and outstanding EMI SE property of 53.5 dB, far exceeding the standard of commercially shielding materials (20 dB). More encouragingly, this work makes a deep insight into the intrinsic connection of porous structure of 3D-printed components on shielding mechanism, which reveals that as the pore size is far less than a certain proportion of incident wavelength (λ/5), the components exhibit a good reconcilability on the lightweight (0.4–1.0 g/cm3) and high-performance EMI SE (35–45 dB). From fundamental materials to desirable components, this breakthrough lays a solid foundation for the free-construction of diversified architectures in EMI SE applications. [Display omitted] • The strong conductive networks are constructed by the hybridization of graphene nanosheets and carbon nanotubes. • The hybrid networks endow the 3D-printed components with superior electromagnetic interference shielding (∼53.5 dB). • The diameter of porous structures should be less than the 1/5 of incident wavelength (λ) to shield electromagnetic waves. • The 3D-printed honeycombs exhibit a good reconcilability on lightweight and electromagnetic interference shielding. [ABSTRACT FROM AUTHOR]