Direct-write/cure conductive polymer nanocomposites for 3D structural electronics

The use of direct-write (DW) in the fabrication of conductive structures offers dramatic benefits over traditional technologies in terms of low-cost, print-on-demand conformal manufacturing. This DW process can be combined with direct-cure (DC) process as one-step manufacturing of conducting elements, whereas conventional methods need a manufacturing process of conducting elements followed by a relatively long time post-curing/baking process. A hybrid technology combined with direct-write/cure (DWC) and projection microstereolithography (P mu SL) is presented in this work. Carbon nanotubes (CNTs) were dispersed in a photopolymer solution to introduce conductivity. The developed P mu SL was used to create 3D structures, and DWC of conductive photopolymers with CNTs was utilized to produce conductive paths. To show the capabilities of the developed system and materials, a 3D structure with embedded conductive paths was designed and fabricated. Based on the experiments, it is thought that the suggested manufacturing process and materials are promising to produce 3D structural electronics.