Composites based on metallic particles and tuned filling factor for 3D-printing by Fused Deposition Modeling

Additive manufacturing of objects made of composite materials is an emerging technology of great interest for high-technological applications allowing fast and precise fabrication of functional objects with tuned properties and few geometrical restrictions. Herein, we report on the synthesis by solution casting of homogeneous composites with tuned amount of gas-atomized metallic particles embedded in polymer. Composites were extruded into filaments for 3D-printing by Fused Deposition Modeling. The obtained results reveal that composites filling factor, suited to obtain continuous and flexible filament, is strongly influenced by particle size and its distribution. Magnetometry appears as a low-time consuming technique for accurately quantifying the magnetic composites filling factor. Moreover, the analysis of magnetic properties of composites and filaments revealed no deterioration of particles during processing. The reported processing techniques were demonstrated to be suitable to produce metal-based filaments for 3D-printing of pieces with non-restricted shape and potential applicability in aeronautics and aerospace sectors.