Periodic Reporting for period 2 - Graphene 3D (Multifunctional Graphene-based Nanocomposites with Robust Electromagnetic and Thermal Properties for 3D-printing Application)
Période du rapport: 2019-01-01 au 2022-09-30
The advantages of graphene and other nanocarbon structures in fabrication of innovative polymer nanocomposite materials for application in Additive Manufacturing (AM), e.g. 3D printing, are enormous. Such nanofillers may provide extraordinary multifunctional properties of the engineering and natural polymers, thus greatly expanding the ranges of applications of products resulted from the innovative 3D printing 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. To answer the needs, the Graphene 3D project aims to develop novel reliable and multifunctional polymer nanocomposite materials incorporating graphene nanoplatelets (GNP) or graphene oxide (GO) and multi-walled carbon nanotubes (MWCNT) 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.
The Graphene 3D project objectives in Annex 1:
1. To develop effective processing techniques for fabrication of graphene-based polymer composites and propose rheological method for control on the processing and structure parameters;
2. To achieve highly improved nanocomposite properties (electrical, electromagnetic, mechanical, thermal) at low percolation threshold and determine the microstructure features that govern the properties enhancement;
3. Propose robust design tool to optimize formulation of nanocomposite material with superior properties suitable for 3D printing application - fused deposition modelling (FDM), and selective laser sintering (SLS);
4. Design nanocomposite cellular structures with optimum configuration (structure, geometry) and improved multifunctional characteristics in view of predefined performances.
5. Prove of design concept by fabrication and experimental validation of 3D printed cellular structures with tunable multifunctional properties
6. Create a "Joint Laboratory on Graphene-Polymer Research" for knowledge share having long-term implication after the project end.
The Graphene 3D project objectives in Annex 1:
1. To develop effective processing techniques for fabrication of graphene-based polymer composites and propose rheological method for control on the processing and structure parameters;
2. To achieve highly improved nanocomposite properties (electrical, electromagnetic, mechanical, thermal) at low percolation threshold and determine the microstructure features that govern the properties enhancement;
3. Propose robust design tool to optimize formulation of nanocomposite material with superior properties suitable for 3D printing application - fused deposition modelling (FDM), and selective laser sintering (SLS);
4. Design nanocomposite cellular structures with optimum configuration (structure, geometry) and improved multifunctional characteristics in view of predefined performances.
5. Prove of design concept by fabrication and experimental validation of 3D printed cellular structures with tunable multifunctional properties
6. Create a "Joint Laboratory on Graphene-Polymer Research" for knowledge share having long-term implication after the project end.
The Graphene 3D project has resulted in several important outcomes:
(1) Novel multifunctional polymeric materials incorporating graphene nanoplatelets, carbon nanotubes, and their hybrids (GNP/MWCNT) have been developed using innovative processing methods. Four prototypes have been fabricated, characterized and validated for 3D printing applications, FDM and SLS technologies, as follows:
- Multifunctional PLA-based hybrid composite filament (FDM), fabricated by controlled extrusion;
- PLA-based composite filament (FDM), produced by “local enrichment technology”;
- HAVOH-based composite filament (FDM), produced by “solvent assisted” method;
- TPU-based composite powder for SLS printers, produced by “powder wrapping” technique.
(2) Multifunctional 3D printed cellular structures with tunable electromagnetic, thermal and mechanical properties have been designed by modeling and simulation approaches. Four experimentally validated 3D-printed prototypes of cellular structures have been proposed:
- Anechoic structure for compact microwave absorbers;
- Periodic open-cell structures for protecting against electromagnetic perturbations;
- "Waffle" structure with improved thermal conductivity; and
- Nested “Russian doll” porosity structure for piezo resistive applications.
(3) Dissemination of the Project results by:
- 76 peer review publications, 33 of them “open access”; 20 invited talks and many posters in International conferences;
- 4 workshops and a Training school were organized within the Graphene 3D project;
- Intellectual Property Ownership Agreement was elaborated to be in force within 5 years after the project end.
(4) A great outcome of the project is certainly the creation the Joint Laboratory on Graphene-Polymer Research and Application, aimed at pursuing a long-lasting structured research and providing training program among its members. The internal organization of the Joint Lab has been agreed in the MC meeting on 2 August 2022, during the Final Workshop on Graphene 3D project, at UEF, Joensuu, Finland, where the three Boards and the Director have been elected. The Joint Lab intends to become an actor for meeting world great challenges brought about by the prominence of sustainable use of materials, energy transition, health care etc. Thanks the multi-sectorial and trans-continental collaborations built within Graphene-3D, the Joint Lab has master cards in hands (additive manufacturing, nanocarbons, multifunctional materials).
(1) Novel multifunctional polymeric materials incorporating graphene nanoplatelets, carbon nanotubes, and their hybrids (GNP/MWCNT) have been developed using innovative processing methods. Four prototypes have been fabricated, characterized and validated for 3D printing applications, FDM and SLS technologies, as follows:
- Multifunctional PLA-based hybrid composite filament (FDM), fabricated by controlled extrusion;
- PLA-based composite filament (FDM), produced by “local enrichment technology”;
- HAVOH-based composite filament (FDM), produced by “solvent assisted” method;
- TPU-based composite powder for SLS printers, produced by “powder wrapping” technique.
(2) Multifunctional 3D printed cellular structures with tunable electromagnetic, thermal and mechanical properties have been designed by modeling and simulation approaches. Four experimentally validated 3D-printed prototypes of cellular structures have been proposed:
- Anechoic structure for compact microwave absorbers;
- Periodic open-cell structures for protecting against electromagnetic perturbations;
- "Waffle" structure with improved thermal conductivity; and
- Nested “Russian doll” porosity structure for piezo resistive applications.
(3) Dissemination of the Project results by:
- 76 peer review publications, 33 of them “open access”; 20 invited talks and many posters in International conferences;
- 4 workshops and a Training school were organized within the Graphene 3D project;
- Intellectual Property Ownership Agreement was elaborated to be in force within 5 years after the project end.
(4) A great outcome of the project is certainly the creation the Joint Laboratory on Graphene-Polymer Research and Application, aimed at pursuing a long-lasting structured research and providing training program among its members. The internal organization of the Joint Lab has been agreed in the MC meeting on 2 August 2022, during the Final Workshop on Graphene 3D project, at UEF, Joensuu, Finland, where the three Boards and the Director have been elected. The Joint Lab intends to become an actor for meeting world great challenges brought about by the prominence of sustainable use of materials, energy transition, health care etc. Thanks the multi-sectorial and trans-continental collaborations built within Graphene-3D, the Joint Lab has master cards in hands (additive manufacturing, nanocarbons, multifunctional materials).
The progress beyond the state of the art of Graphene 3D project is significant and it is based on the following achievements:
(i) original, controllable processing technologies for Graphene/MWCNT/polymer nanocomposites for 3D printing applications (FDM and SLS) have been developed;
(ii) innovative robust nanocomposite design tool have been developed for optimizing the process-structure-property-performance variables;
(iii) optimized nanocomposite material formulations have been fabricated and experimentally characterized in respect to the structure, electrical, electromagnetic, thermal and mechanical properties;
(iv) multifunctional foam-like and spongy open cellular structures have been 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 have been produced by 3D printing and then experimentally validated to achieve the predefined model properties. Four prototypes have been selected with strong potential for application in high power electronics (e.g. in sensors, detectors, heat exchangers).
The intercontinental network involving industrial countries Brazil and China, created within the Graphene 3D project has strongly enhanced the research and innovation potential of the participants and has contributed positively to the career of ESRs and ERs of the 10 project participants.
Consortium members benefit strongly from the project interdisciplinary nature which has enhanced the research quality, the scientific reputation and provide the launching pad for future collaborative ventures.
(i) original, controllable processing technologies for Graphene/MWCNT/polymer nanocomposites for 3D printing applications (FDM and SLS) have been developed;
(ii) innovative robust nanocomposite design tool have been developed for optimizing the process-structure-property-performance variables;
(iii) optimized nanocomposite material formulations have been fabricated and experimentally characterized in respect to the structure, electrical, electromagnetic, thermal and mechanical properties;
(iv) multifunctional foam-like and spongy open cellular structures have been 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 have been produced by 3D printing and then experimentally validated to achieve the predefined model properties. Four prototypes have been selected with strong potential for application in high power electronics (e.g. in sensors, detectors, heat exchangers).
The intercontinental network involving industrial countries Brazil and China, created within the Graphene 3D project has strongly enhanced the research and innovation potential of the participants and has contributed positively to the career of ESRs and ERs of the 10 project participants.
Consortium members benefit strongly from the project interdisciplinary nature which has enhanced the research quality, the scientific reputation and provide the launching pad for future collaborative ventures.