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Mechanical and strain sensing capabilities of carbon nanotube (CNT) reinforced composites manufactured by digital light processing (DLP) 3D printing technology have been studied. Both CNT content and a post-curing treatment effects have been analyzed. It has been observed that post-curing treatment has a significant influence on mechanical properties, with an increase of Young’s modulus and glass transition temperature whereas their effect in electrical properties is not so important. Furthermore, the strain sensing tests show a linear response of electrical resistance with applied strain, with higher values of sensitivity when decreasing CNT content due to a higher interparticle distance. Moreover, the electrical sensitivity of bending tests is significantly lower than in tensile ones due to the compression subjected face effect. Therefore, the good gauge factor values (around 2–3) and the high linear response proves the applicability of the proposed nanocomposites in structural health monitoring applications.

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A novel nanoreinforced adhesive film has been developed to detect adhesive deformation and crack propagation along the bonding line by means of the electrical response of the material. Adhesive films were doped by spraying an aqueous dispersion of carbon nanotubes (CNTs) over the surface. To determine the sensitivity of bonded joints, single lap shear (SLS) and mode-I fracture energy tests have been carried out while their electrical response has been measured. It has been found that CNT-doped adhesive films are able to detect adhesive deformation and final failure for SLS specimens and crack initiation and propagation along the bonding line for mode-I specimens with a high sensitivity. Sudden increases on electrical resistance are correlated to a rapid growing of the crack length due to instability on crack propagation in a tick-slip case, whereas specimens with a more uniform crack propagation are linked to a steadier increase on electrical resistance, and both of them are properly correlated to the mechanical response. By analyzing more in detail the electrical response and comparing with theoretical approaches, the stick-slip behavior is associated with the presence of porosity and lack of adhesives because of possible manufacturing issues such as adhesive overflowing. These statements are also validated by microstructural analysis. Therefore, the potential and applicability of the proposed adhesive films for evaluating the structural integrity has been demonstrated.

A performance mapping of GNP/epoxy composites was developed according to their electromechanical and electrothermal properties for applications as strain sensors and Joule heaters. To achieve this purpose, a deep theoretical and experimental study of the thermal and electrical conductivity of nanocomposites has been carried out, determining the influence of both nanofiller content and sonication time. Concerning dispersion procedure, at lower contents, higher sonication times induce a decrease of thermal and electrical conductivity due to a more prevalent GNP breakage effect. However, at higher GNP contents, sonication time implies an enhancement of both electrical and thermal properties due to a prevalence of exfoliating mechanisms. Strain monitoring tests indicate that electrical sensitivity increases in an opposite way than electrical conductivity, due to a higher prevalence of tunneling mechanisms, with the 5 wt.% specimens being those with the best results. Moreover, Joule heating tests showed the dominant role of electrical mechanisms on the effectiveness of resistive heating, with the 8 wt.% GNP samples being those with the best capabilities. By taking the different functionalities into account, it can be concluded that 5 wt.% samples with 1 h sonication time are the most balanced for electrothermal applications, as shown in a radar chart.

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