Innovative processing route combining fused deposition modelling and laser writing for the manufacturing of multifunctional polyamide/carbon fiber composites

An innovative manufacturingmethod, based on Fused DepositionModelling (FDM) and LaserWriting (LW)technologies, was developed to integrate electrically conductive trackswithin high strength 3D printed parts. Carbon fibers reinforced polyamide composites were processed by FDM according to three different printing architectures by varying the raster angle in the layer sequence. Laser writing was then performed to obtain conductive tracks on the surface of the printed parts. The process-structure-property relationship of components before and after thewriting of conductive tracks was investigated. The tensile behaviour and the track resistance of samples were correlated to the direction of filament extrusion within the layers, and consequently to fibers orientation. Tracks showing good aesthetic quality and the lowest electrical resistance were obtained on samples with [±45] architecture. These tracks displayed the lowest electrical resistance ever reached by laser writing on metal-free polymer composites (0.008 kΩ/cm). Samples with [±45] architecture also showed high strength (72.9 MPa) and stiffness (7.7 GPa). The integration of FDM and LW emerges as a new approach to transform the surface of high strength polymer composites parts into a highly valuable system. These multifunctional components can find applications in several industrial fields such as automotive, aeronautics, and appliances.