Electromagnetic interference shielding performance of carbon nanostructure reinforced, 3D printed polymer composites

Abstract

We report the electrical, mechanical and electromagnetic interference (EMI) shielding performance of polypropylene random copolymer (PPR)/multi-wall carbon nanotube (MWCNT) nanocomposites enabled via customized fused filament fabrication process. The electro-conductive PPR/MWCNT filament feedstocks were fabricated via shear-induced melt-blending process that allows 3D printing of nanoengineered composites even at higher MWCNT loading (up to 8 wt%). The uniform dispersion of MWCNTs in PPR matrix confirmed via Raman spectroscopy and scanning electron microscopy facilitates better mechanical, electrical and EMI shielding performance. The results furthermore show enhanced shielding properties and higher attenuation for the nanocomposites printed in 90° direction (~ − 37 dB for 8 wt% MWCNT loading). Effective interfacial adhesion between the beads with lesser extent of voids (confirmed via micro-computed tomography) endorsed low transmission loss in nanocomposites printed in 90° direction compared to samples printed in 0° direction. Surface architected structure (frustum shape) reveals higher specific shielding effectiveness (maximum ~ − 40 dBg−1cm3, + 38%) over the plain structure. The realization of excellent shielding effectiveness (~ 99.9% attenuation) of additive manufacturing-enabled PPR/MWCNT nanocomposites demonstrates their potential for lightweight and strong EMI shields. Graphical Abstract

Review on engineering designing of electromagnetic interference shielding materials using additive manufacturing

“…Due to their compatibility characteristics with the fusion and extrusion process of 3D printing and inherent properties required for shielding electromagnetic waves, the specific type of raw materials can be used to fabricate EMI shielding material using unique 3D printing processing. The different raw materials like PLA, [43][44][45]51,52] poly (3,4-ethylene dioxythiophene): poly (styrene sulfonic acid), [48] polypropylene random copolymer, [50] graphene nanofilms, [46] CNT, MWCNT, and CB has been used for developing EMI shielding material as shown in Figure 14 given below.…”

“…The researchers mainly used the 3D printing technique, namely fused filament fabrication or fused deposition modeling (FFF/FDM), [43,44,47] Solvent cast 3D printing, [45] Spin coating, and drop-casting, [50] for developing EMI shielding material.…”

“…3D printing gives an edge over conventional manufacturing when it comes to preparing designs of various requirements, which cannot be consistently achieved by traditional manufacturing. (Figures 15 and 16) [50] Abbreviations: ABS, acrylonitrile butadiene styrene; BML, black magic; CNT, carbon nanotube; EMI SE, electromagnetic interference shielding effectiveness; FDM, fused deposition modeling; FFF, fused filament fabrication; MWCNT, multiwalled carbon nanotube.…”

“…Further samples with 6 and 8 wt% MWCNT load showed high conductivity of 10 3 S/cm. [50] F I G U R E 1 1 SEM images of the 3D printed (A-C) and solid mixture processed (E, F, and G) polymer composite. SEM, scanning electron microscope.…”

Cold spray deposition of metallic coatings on polymers: a review

“…In recent years, polymer and fibre-reinforced polymers (FRPs) are gaining interest due to their specific properties in various fields, such as in aerospace and military [25][26][27]. Several applications of these materials are still excluded, to date, because they are not capable to ensure some specific properties successfully, such as electrical conductivity, electromagnetic shielding, thermal conductivity, erosion, radiation, and lightning protection [28][29][30][31][32]. For example, when applying PMCs on an aircraft body, a surface conductive path is required to avoid damage from lightning strikes and thunderstorm electric field attacks.…”