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Three-Dimensional Printing of Abrasive, Hard, and Thermally Conductive Synthetic Microdiamond-Polymer Composite Using Low-Cost Fused Deposition Modeling Printer

Journal Article


Abstract


  • 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%.

UOW Authors


  •   Waheed, Sidra (external author)
  •   Cabot, Joan M. (external author)
  •   Smejkal, Petr (external author)
  •   Farajikhah, Syamak (external author)
  •   Sayyar, Sepidar
  •   Innis, Peter
  •   Beirne, Stephen
  •   Barnsley, Grant (external author)
  •   Lewis, Trevor W. (external author)
  •   Breadmore, Michael C. (external author)
  •   Paull, Brett (external author)

Publication Date


  • 2019

Citation


  • Waheed, S., Cabot, J. M., Smejkal, P., Farajikhah, S., Sayyar, S., Innis, P. C., Beirne, S., Barnsley, G., Lewis, T. W., Breadmore, M. C. & Paull, B. (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, 11 (4), 4353-4363.

Scopus Eid


  • 2-s2.0-85060846027

Number Of Pages


  • 10

Start Page


  • 4353

End Page


  • 4363

Volume


  • 11

Issue


  • 4

Place Of Publication


  • United States

Abstract


  • 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%.

UOW Authors


  •   Waheed, Sidra (external author)
  •   Cabot, Joan M. (external author)
  •   Smejkal, Petr (external author)
  •   Farajikhah, Syamak (external author)
  •   Sayyar, Sepidar
  •   Innis, Peter
  •   Beirne, Stephen
  •   Barnsley, Grant (external author)
  •   Lewis, Trevor W. (external author)
  •   Breadmore, Michael C. (external author)
  •   Paull, Brett (external author)

Publication Date


  • 2019

Citation


  • Waheed, S., Cabot, J. M., Smejkal, P., Farajikhah, S., Sayyar, S., Innis, P. C., Beirne, S., Barnsley, G., Lewis, T. W., Breadmore, M. C. & Paull, B. (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, 11 (4), 4353-4363.

Scopus Eid


  • 2-s2.0-85060846027

Number Of Pages


  • 10

Start Page


  • 4353

End Page


  • 4363

Volume


  • 11

Issue


  • 4

Place Of Publication


  • United States