Additive Manufacturing of Polymer Composites with Printing-Direction-Independent Properties

The implementation of additive manufacturing techniques for thermal management applications necessitates the development of printable materials with enhanced properties. This study focuses on enhancing the thermal and mechanical properties of 3D-printed polymer composites (UV-based vat photopolymerization; VPP), starting by loading graphene nanoplatelets (GNP) as fillers into a monomer solution. GNP stabilization in the solution is achieved via the addition of sepiolite, a fiber-like clay, that traps them in dispersion. However, the inherent GNP-UV blocking limits its concentration in the VPP-printed composite, and its 2D nature yields parts with undesired anisotropic properties. We overcome this GNP concentration limit by using the excluded volume approach, namely, adding micron-sized diamonds to increase the GNP effective concentration. This approach also transforms the anisotropic VPP-printed composite into an isotropic structure, ensuring consistent thermal and mechanical enhancement regardless of the printing direction. Thermal conductivity (TC) and fracture toughness (FT) are enhanced by 180% and 100%, respectively (vs. the neat polymer). However, the electrical conductivity (EC) is also enhanced, which is undesirable in thermal management systems (risk of short-circuiting). Therefore, hexagonal boron nitride is added to reduce the EC, producing composites with enhanced TC and 140% FT enhancement. Our approach holds promise for various applications, especially in advanced heat management solutions, where enhanced TC, light weight, and low EC are imperative.