(539b) Enhancing Production and Functional Properties of Composites Using 3D Printing

Nanoparticle-reinforced composites represent cutting-edge materials renowned for their directional properties and enhanced physical and chemical characteristics. However, achieving peak performance requires evenly dispersing nanoparticles, establishing robust particle-matrix bonds, and attaining optimal alignment with uniaxial orientation. 3D printing holds promise for achieving precise nanoparticle orientation, including 1D and 2D particles, while offering customizable structures, reduced lead times, and minimal material wastage. In this study, we introduce a novel nozzle design inspired by natural layered structures, facilitating the creation of layered composites. This unique nozzle processes two immiscible feedstocks simultaneously—polymer or nanoparticle dispersions and polymer blends—and arranges them in an alternating pattern within a single element. The modular nozzle design allows for adjusting the number of alternating layers, influencing nanoparticle and polymer chain alignment and packing efficiency. The nozzle was specifically designed for additive manufacturing, featuring an intricate internal design to efficiently rearrange the feedstocks into alternating layers. Studies were conducted focusing on fiber production, with an emphasis on moderating thermal properties for textile applications. The nozzle was seamlessly integrated into a 3D printing platform to create a simplified composite printing mechanism and enable micro-patterning for electronic applications. This approach demonstrates versatility through various polymer-nanoparticle combinations, showcasing applications such as textile fabrics, electronics thermal management, smart materials, and soft robotics. By leveraging the advantages of 3D printing, precise control over nanoparticle alignment and packing factors was achieved, showing promising potential for significant performance enhancements across diverse industries. The modular design of the nozzle also unlocks new opportunities for tailored advanced composites.