Electrical Network Activation in 3D Printed Thermoset Composites via Nozzle Oscillation Infill Pattern

Abstract This study presents a novel approach to manufacture electrically conductive thermoset-based carbon fiber reinforced polymer (CFRP) composites with enhanced print quality. Nozzle oscillation infill patterns were developed to suppress the shear induced fiber alignment during printing. This method generates a randomly aligned fiber microstructure which exhibits an activated electrical network throughout the material. After finding the best printing pattern in terms of electrical conductivity and dimensional accuracy by an optimization study, CFRP parts were produced utilizing Direct Ink Writing (DIW) 3D printing process. Printed specimens were analyzed to evaluate electrical conductivity and part quality. The results show that, by utilizing the presented oscillation infill printing, 27% higher electrical conductivity was achieved with an exceptional dimensional accuracy (dimensional error decrease of 6.81% for the thickness, 2.44% and 2.97% for the length directions) compared to the state-of-the-art over-extrusion process. This study emphasizes that oscillation infill pattern printing is a promising technique for fabricating advanced composites with enhanced spatial conductivity control and dimensional stability.