Investigation on using graphite filler for 3D printing of flexible electrically conductive polymer by extrusion‐based additive manufacturing.

The rapid use of additive manufacturing (AM) in electronic industry identifies the need of flexible electrically conductive materials suitable for 3D printing. Challenges like buckling of flexible filament and complexity in addition of conductive fillers makes pellet‐based extrusion the most suitable alternative for part printing. In the present work, graphite powder is combined with ethylene vinyl acetate (EVA) to print flexible electrically conductive parts. EVA graphite composite with filler loading up to 30% has been investigated for its electrical conductivity and part printability. The composite made was found electrically conductive and suitable for part printing. The parts were printed on a CNC milling machine by using a retrofitted material extrusion tool with nozzle of 0.4 mm diameter and temperature range of 130–140°C. Parts were printed on a detchable heating bed placed on the milling machine setup. Samples of EVA with graphite filler by weight of 5%, 10%, 20%, and 30% were printed and were checked for electrical conductivity. When the filler content was increased from 10% to 20%, the electrical resistance of the composite was reduced by 62.6%. The presence and uniform dispersion of graphite flakes in the polymer matrix of EVA were guaranteed by the rheological and morphological characterization of the composite. Applications of 3D printable flexible electrically conductive parts lies in numerous domains including biosensors, wearable health monitoring devices, capacitors, field effective transistors, light emitting diodes, solar cells, and electronic displays. Highlights: CNC milling machine‐assisted 3D printing is used for part printing.Graphite powder is combined with EVA pellets.Pellet‐based extrusion is used to print flexible parts.3D printability of parts with resistivity 32.64 Ω‐cm was achieved. [ABSTRACT FROM AUTHOR]