Enhancing nanomaterial dispersion and performance of parts printed via FFF by a solution casting method

Nanocomposites represent an important way to expand the boundaries of material-property space. To advance their use in printing by fused filament fabrication (FFF), we develop a method based on colloidal solution mixing to improve dispersion of various nanofiller additives in printed parts. Printed nanocomposites exhibit increases in Young’s modulus of up to 41%, decreases in part-to-part variation, and the ability to reach higher nanofiller loading levels. Optical microscopy shows a reduction in nanofiller aggregates in parts created using this solution casting method. Improvements in printability, quality, and performance of FFF-printed parts may accelerate the utility of nanocomposites in FFF. Graphic Abstract