Polypropylene‐Based 3D Printed Skin‐Core Structures With Thermal Conductivity and Balanced Mechanical Properties

ABSTRACT In this work, polypropylene (PP)‐based filaments for Fused Filament Fabrication (FFF) containing boron nitride (BN) or talc (T) were developed and used to formulate multi‐functional 3D‐printed parts with enhanced thermal conductivity and mechanical properties. More specifically, skin‐core structures, with BN in surface layers and talc in the core, were optimized and characterized. Results show that confining BN to surface layers improves in‐plane thermal conductivity due to filler alignment during printing. Furthermore, the obtained structures maintain mechanical properties comparable to PP/T mono‐material samples, despite reduced filler content and the presence of multi‐material interfaces, demonstrating the potential of the proposed strategy for creating high‐performance multi‐material parts through FFF.