Extrusion-based additive manufacturing of aluminium-filled ethylene vinyl acetate for electrically conductive 3D part printing

Addition of carbon-based fillers to enhance electrical conductivity is quite popular but addition of metal fillers is still a challenge due to oxidation and unavailability of metal nano-powders. In this paper, fabrication of flexible electrically conductive parts is proposed using aluminium metal powder as filler material. Aluminium metal powder is mixed with ethylene vinyl acetate (EVA) by chemical mixing process. Cyclohexane is used as a mixing medium in which EVA is dissolved and aluminium powder is added by weight. An in-house developed material extrusion tool mounted on CNC milling machine is used for printing of flexible electrically conductive samples. Pellet-based extrusion process is used for printing flexible parts as conventional filament-based 3D is not suitable due to buckling. Composite with filler loading in 5%, 10%, 20% and 30% were made and samples were printed. Investigations were made on printability of composite and its electrical conductivity. The aluminium fillers presence and dispersion in polymer were ensured. The samples were printed in temperature range of 130-140 degrees C through 0.4 mm diameter nozzle. It was found that the resistivity drops by around 60% on varying the filler concentration from 20% to 30%; 81.6 k omega is the lowest resistance observed with 30% filler concentration. A simulation study on thermal behaviour of material extrusion tool has been done and is validated practically. The application of flexible electrically conductive parts lies in fabrication of various electronic devices like antenna, display boards, solar panels, and wearable health monitoring devices.