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Additive manufacturing (AM) of components using material extrusion (MEX) offers the potential for the integration of functions through the use of multi-material design, such as sensors, actuators, energy storage, and electrical connections. However, there is a significant gap in the availability of electrical composite properties, which is essential for informed design of electrical functional structures in the product development process. This study addresses this gap by systematically evaluating the resistivity (DC, direct current) of 14 commercially available filaments as unprocessed filament feedstock, extruded fibers, and fabricated MEX-structures. The analysis of the MEX-structures considers the influence of anisotropic electrical properties induced by the selective material deposition inherent to MEX. The results demonstrate that composites containing fillers with a high aspect ratio, such as carbon nanotubes (CNT) and graphene, significantly enhance conductivity and improve the reproducibility of MEX structures. Notably, the extrusion of filaments into MEX structures generally leads to an increase in resistivity; however, composites with CNT or graphene exhibit less reduction in conductivity and lower variability compared to those containing only carbon black (CB) or graphite. These findings underscore the importance of filler selection and composition in optimizing the electrical performance of MEX structures. [ABSTRACT FROM AUTHOR]

The additive manufacturing of components using material extrusion (MEX) enables the integration of several materials into one component, including functional structures such as electrically conductive structures. This study investigated the influence of the selected additive MEX process on the resistivity of MEX structures. Specimens were produced from filaments and granules of an electrically conductive PLA and filled with carbon nanotubes and carbon black. Specimens were produced with a full-factorial variation of the input variables: extrusion temperature, deposition speed, and production process. The resistivity of the specimens was determined by four-wire measurement. Analysis of the obtained data showed that only the extrusion temperature had a significant influence on the resistivity of the MEX specimens. Furthermore, the impact of the nozzle diameter was evaluated by comparing the results of this study with those of a previous study, with an otherwise equal experimental setup. The nozzle diameter had a significant influence on resistivity and a larger nozzle diameter reduced the mean variance by an order of magnitude. The resistivity was lower for most process parameter sets. As the manufacturing process had no significant influence on the resistivity of MEX structures, it can be selected based on other criteria, e.g., the cost of feedstock. [ABSTRACT FROM AUTHOR]

Additive manufacturing of components using the material extrusion (MEX) of thermoplastics enables the integration of multiple materials into a single part. This can include functional structures, such as electrically conductive ones. The resulting functional structure properties depend on the process parameters along the entire manufacturing chain. The aim of this investigation is to determine the influence of process parameters in filament production and additive manufacturing on resistivity. Filament is produced from a commercially available composite of polylactide (PLA) with carbon nanotubes (CNT) and carbon black (CB), while the temperature profile and screw speed were varied. MEX specimens were produced using a full-factorial variation in extrusion temperature, layer height and deposition speed from the most and least conductive in-house-produced filament and the commercially available filament from the same composite. The results show that the temperature profile during filament production influences the resistivity. The commercially available filament has a lower conductivity than the in-house-produced filament, even though the starting feedstock is the same. The process parameters during filament production are the main factors influencing the resistivity of an additively manufactured structure. The MEX process parameters have a minimal influence on the resistivity of the used PLA/CNT/CB composite. [ABSTRACT FROM AUTHOR]