Process Parameters for FFF 3D-Printed Conductors for Applications in Sensors.

Area of Science:

• Additive Manufacturing
• Materials Science
• Electrical Engineering

Background:

• Recent advancements in additive manufacturing (AM) enable the fabrication of smart structures using single-process fused-filament fabrication (FFF).
• FFF sensors for dynamic mechanical quantities require conductive filaments, but printed electrical conductors for embedded wiring present challenges due to resistivity limitations.

Purpose of the Study:

• To investigate the Electrifi filament for printed electrical conductors in single-process FFF.
• To optimize printing-process parameters for achieving the highest conductivity in printed conductors.
• To understand the formation and degradation mechanisms of conductive networks in printed materials.

Main Methods:

• Systematic investigation of six printing-process parameters and over 40 parameter values.
• Fabrication and electrical characterization of over 200 conductive samples using Electrifi filament.
• Research into conductor embedding techniques and post-printing heating effects.

Main Results:

• Identified optimal printing strategies that reduced electrical resistivity by approximately 40% compared to the filament's nominal value.
• Gained insights into the mechanisms governing conductive network formation and degradation.
• Demonstrated the potential for significantly improved conductivity in FFF-printed electrical conductors.

Conclusions:

• Optimized printing processes can substantially lower the resistivity of Electrifi filament conductors.
• Understanding conductive network behavior facilitates process improvements and new design strategies for single-process FFF smart structures.
• This research paves the way for more efficient and functional embedded electronics in 3D-printed objects.