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Three-dimensional printing of abrasive, hard, and thermally conductive synthetic microdiamond-polymer composite using low-cost fused deposition modeling printer

Waheed, S ORCID: 0000-0003-1601-4338, Cabot, JM ORCID: 0000-0002-3305-078X, Smejkal, P, Farajikhah, S, Sayyar, S, Innis, PC, Beirne, S, Barnsley, G, Lewis, TW ORCID: 0000-0001-6891-3840, Breadmore, MC ORCID: 0000-0001-5591-4326 and Paull, B ORCID: 0000-0001-6373-6582 2019 , 'Three-dimensional printing of abrasive, hard, and thermally conductive synthetic microdiamond-polymer composite using low-cost fused deposition modeling printer' , ACS Applied Materials and Interfaces, vol. 11, no. 4 , pp. 4353-4363 , doi: 10.1021/acsami.8b18232.

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A relative lack of printable materials with tailored functional properties limits the applicability of three-dimensional (3D) printing. In this work, a diamond–acrylonitrile butadiene styrene (ABS) composite filament for use in 3D printing was created through incorporation of high-pressure and high-temperature (HPHT) synthetic microdiamonds as a filler. Homogenously distributed diamond composite filaments, containing either 37.5 or 60 wt % microdiamonds, were formed through preblending the diamond powder with ABS, followed by subsequent multiple fiber extrusions. The thermal conductivity of the ABS base material increased from 0.17 to 0.94 W/(m·K), more than five-fold following incorporation of the microdiamonds. The elastic modulus for the 60 wt % microdiamond containing composite material increased by 41.9% with respect to pure ABS, from 1050 to 1490 MPa. The hydrophilicity also increased by 32%. A low-cost fused deposition modeling printer was customized to handle the highly abrasive composite filament by replacing the conventional (stainless-steel) filament feeding gear with a harder titanium gear. To demonstrate improved thermal performance of 3D printed devices using the new composite filament, a number of composite heat sinks were printed and characterized. Heat dissipation measurements demonstrated that 3D printed heat sinks containing 60 wt % diamond increased the thermal dissipation by 42%.

Item Type: Article
Authors/Creators:Waheed, S and Cabot, JM and Smejkal, P and Farajikhah, S and Sayyar, S and Innis, PC and Beirne, S and Barnsley, G and Lewis, TW and Breadmore, MC and Paull, B
Keywords: 3D printing, fused deposition modeling, composite, microdiamonds, thermal conductivity, heat sinks, hydrophilicity, recyclable
Journal or Publication Title: ACS Applied Materials and Interfaces
Publisher: American Chemical Society
ISSN: 1944-8244
DOI / ID Number: 10.1021/acsami.8b18232
Copyright Information:

© 2019 American Chemical Society

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