Hybrid 3D printing and electrospinning technique for the production of air filter materials and the effect of different infill patterns on air permeability

In this study, 3D-printed polylactic acid (PLA) samples with five different infill patterns (trihexagone, grid, gyroid, line and triangle) were covered with electrospun polyacrylonitrile (PAN) nanofibres to investigate their air permeability properties. SEM results showed that PAN electrospun nanofibres were beadless and ordered nanofibres with an average diameter of 260.89 ± 32 nm. The tensile properties and air permeability of the PAN nanofibre-coated 3D-printed PLA samples were investigated. The results showed PAN nanofibre-coated 3D-printed PLA sample with gyroid infill pattern was favoured in terms of mechanical properties among five different infill patterns with its high tensile strain and Young’s modulus values, 4.18% and 977 MPa, respectively. Furthermore, while the air permeability properties of resulting PAN nanofibre-coated PLA materials were analysed, the lowest air permeability which means high particle capturing capability was obtained for line and gyroid with the air permeability values of 42 and 51 l m –2 s –1 . While the mechanical properties and air permeability properties are evaluated together; gyroid with its excellent mechanical properties and low air permeability was favoured among the five different infill patterns. The production of this hybrid material could provide a new approach to the design and development of air filter materials.