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Report

Teaser, summary, work performed and final results

Periodic Reporting for period 1 - Graphene 3D (Multifunctional Graphene-based Nanocomposites with Robust Electromagnetic and Thermal Properties for 3D-printing Application)

Teaser

Summary

The advantages of graphene and other nanocarbon structures in fabrication of innovative polymer nanocomposite materials for application in Additive Manufacturing, e.g. 3D printing, are enormous. Such nanocomposites may provide extraordinary multifunctional properties of engineering and natural polymers, thus greatly expanding the ranges of applications of products resulted from these innovative technologies. Due to the complexity of composition and processing, however, key issue for the mass production of such nanocomposite materials is how to gain control on the dispersion process, interactions phenomena, and structure/morphology in order to obtain superior properties. The attempts to understand and predict the macroscale properties of polymers nanocomposites show that many questions remain unanswered or even un-asked. To answer the needs, the Graph 3D project aims to develop novel reliable and multifunctional polymer nanocomposite material incorporating graphene and multi-walled carbon nanotubes for 3D printing applications, as well as to design and experimentally validate 3D printed lightweight cellular structures with predefined performances, based on the innovative nanocomposites. Graphene 3D project will create a Joint Laboratory on graphene-polymer research for knowledge share within the multidisciplinary international and inter-sectoral consortium having long-term implication on future applications of the nanomaterials.
To reach the goal, the project will pursue the following main objectives: (1) to develop an effective processing technique for graphene-based polymer nanocomposite; (2) to correlate processing variables with final micro and nanostructure features; (3) to obtain highly improved nanocomposite properties (electrical, electromagnetic, mechanical, thermal); (4) to propose robust design tool for optimizing process-structure-property-performance parameters, resulting in optimized nanocomposite formulation for 3D printing application; (5) to design nanocomposite-based cellular structures with optimum configuration (structure, geometry) and tunable multifunctional characteristics in view of predefined performances; (6) to prove the design concept by fabrication and experimental validation of both nanocomposite material and 3D printed cellular structures that achieve unique properties.

Work performed

During the first 24 months of the project implementation, two materials are already fabricated and optimized which, according to the Milestone MS1, will be adopted as outcome of the project as novel materials for 3D printing applications for the preparation of porous lightweight complex structures. Those are:
1) Polylactic acid (PLA-based) nanocomposite incorporating commercial graphene, carbon nanotubes and their mixture, suitable for FDM 3D printing technology (Partners: NanoTechLab, CNR, IMECH)
2) Thermoplastic polyurethane (TPU-based) composite powder, wrapped with commercial graphene and carbon nanotubes, suitable for SLS 3D printing technology (Partners: CNR and SU).
The two materials have already been optimized in terms of procedure for the fabrication and also validated for the 3D printability. These materials (which are produced in different formulation including 1.5 to 12wt% carbon nanotubes, graphene nanoplatelets and mixture of the two filler) are already available and represent a real outcome of the project for printing complex porous structures with interesting electrical, electromagnetic, mechanical and thermal properties. Based on the chain supply of material development, and considering the excellent results obtained in the real printability, it is possible to consider these two composites to have a TRL as high as 5-6. Partners involved in this activity are: CNR, NanoTechLab, IMECH, and the TC partner SU.
Some composites based on the selected carbonaceous fillers (i.e. commercial and project-made carbon nanotubes and graphene and its derivatives) and polymeric matrix such as PDMS (project-synthesized), and commercial HDPE, HAVOH and ABS are still in the phase of optimization despite the preliminary results are very promising (TRL in the range 3-4). These composite materials just need further optimization that will be reasonably carried out in the next twelve months of the WP2, in order to obtain raw materials for the production of SLS powder and/or FDM filament. Partners involved are: SIPT, Narrando, IMECH, CNR, and the TC partners INP, and MackGraphe.

Final results

The Graph 3D project propose innovative research beyond the state-of-the-art aiming to improve knowledge and understanding in basic principles for robust design of graphene-based polymer nanocomposites and fabrication of efficient nanocomposite materials for 3D printing application.

The following novel achievements are foreseen in the Graphene 3D project:
(i) original, controllable processing technology for graphene/MWCNT/polymer nanocomposites will be proposed using rheological methods for the estimation of the degree of nanofiller dispersion, the interfacial nanofiller-polymer interactions, and the rheological percolation threshold;
(ii) innovative robust nanocomposite design tool will be developed for optimizing the process-structure-property-performance variables in view of producing multifunctional polymer nanocomposite with desired properties for 3D printing application;
(iii) novel, robust optimized nanocomposite material formulation will be fabricated and experimentally characterized in respect to the structure, electrical, electromagnetic, thermal and mechanical properties of the material, as well as correlated with modelling parameters to minimize variations. Data-sheet with essential properties of the novel multifunctional nanocomposite will be created and correlated with Technical specifications of the commercially available materials for 3D printing application;
(iv) multifunctional foam-like and spongy open cellular structures will be specially designed to cumulate unique lightness, stiffness, high electrical and thermal conductivity, and almost perfect electromagnetic absorbance in the range 1-100 GHz;
(v) prototypes of the designed cellular structures will be produced by 3D printing, using the novel graphene/ MWCNT/polymer material, and then experimentally validated to achieve the predefined model properties. This will be the first innovative 3D printed cellular structures, optimized priory with specific performances, that have a strong potential for application in high power electronics (e.g. in sensors, detectors, heat exchangers).

The project proposes to link synergistically three emerging multisectoral fields of activity: graphene-polymer nanotechnology; materialsâ€™ design; and additive manufacturing. Each of these fields is receiving growing interest by the EU market.
The intercontinental network involving industrial countries Brazil and China, created within this MSCA proposal will enhance strongly the research and innovation potential of EU MS participants towards market application and impact strongly the innovation potential based on graphene nanomaterials design.
Consortium members will benefit from the project interdisciplinary nature which will enhance the research quality, the scientific reputation and provide the launching pad for future collaborative ventures