Evaluating the Electromagnetic Shielding of Continuous Carbon Fiber Parts Produced by Additive Manufacturing

Electronic devices are sensitive to electromagnetic (EM) emissions, and require electromagnetic shielding protection to ensure good operation, and prevent noise, malfunctioning, or even burning. To ensure protection, it is important to develop suitable material and design solutions for electronic enclosures. Most common enclosures are made with metal alloys using traditional manufacturing methods. However, using thermoplastic composites combined with additive manufacturing (AM) technologies emerges as an alternative that enables the fabrication of complex parts that are lightweight, consolidated, and oxidation- and corrosion-resistant. In this research, an AM technique based on material extrusion was used to print 2 mm-thick specimens with a multi-material made of micro-carbon fiber (CF)-filled polyamide that was reinforced at specific layers using continuous carbon fibers stacked with a 90° rotation to each other. The specimens' electromagnetic shielding effectiveness (EMSE) was evaluated in the frequency band of 0.03-3 GHz using the coaxial transmission line method. Depending on the number of CF layers, the EM shielding obtained can be up to 70 dB, with a specific shielding up to 60 dB.cm³/g, predominantly by the absorption mechanism, being 22 times higher than without the CF layers. These findings promote this innovative approach to lightweight customizable solutions for EM shielding applications.