Characterization and applications of electrically-conductive filament in 3D printing

Abstract

Three dimensional printing (3D printing) a form of rapid prototyping has been conceived by Charles W. Hull in 1986. As design patents pertaining to expensive commercial 3D printers expire, more affordable 3D printers are emerging. One particular 3D printing technology that has become very popular is Fused Filament Fabrication (FFF). The widespread acceptance of FFF printers has boosted the demand for new types of filaments with different properties. Filament composites can provide 3D prints with additional functionality. There is a need to characterize new filaments and to develop novel applications that will further push the boundaries of this technology. This research explores the use and characterization of electrically-conductive Carbon Black plastic composite filament in conjunction with desktop FFF printers. Electrically-conductive graphene plastic composite is also characterized based on these results. Resistors, capacitors, and inductors are designed, created, and characterized. Based on these findings, capacitive touch and flexure sensors are designed, implemented, and characterized. A small musical keyboard is designed and built to showcase the use of readily available conductive filament in low cost 3D printers. Finally, 3D printing process best practices and improvements are detailed, and additional recommendations are made.