3D printing of functionally graded nanocomposites: An investigation of microstructural, rheological, and mechanical behavior

Manufacturing functionally graded material through 3D printing is challenging owing to the deposition of different materials with different thermal properties in each layer, leading to a higher thermal gradient between deposited and depositing layers, resulting in improper bonding between them and, hence, reduced mechanical properties. This study focuses on 3D printing of functionalized multi‐walled carbon nanotubes (MWCNTs)/high‐density polyethylene (HDPE)‐based lightweight functionally graded nanocomposites (FGNCs) and their investigation for microstructural, rheological, physical, and mechanical properties. Functionalized MWCNTs (0.5% → 5%) are initially compounded with widely utilized HDPE to develop nanocomposites (H0.5→H5 pellets) for extruding filaments for 3D printing. 3D‐printed FGNC samples are investigated through scanning electron microscopy (SEM), rheology, density, tensile, and flexural tests. SEM and rheology confirm the homogeneous dispersion of the filler in HDPE and the processing parameters suitability in blending, extrusion, and 3D printing. Complex viscosity (η*), loss modulus (E″), and storage modulus (E′) of FGNCs increase, while the damping decreases with the MWCNTs rise in the graded layers. Density results revealed the highest weight saving potential (~12%) of FGNC‐2 (H1–H3–H5), showing great weight saving potential. Tensile and flexural properties rise when the MWCNTs content rises in the graded layer. The FGNC‐2 showed the highest tensile strength and moduli, 37.12% and 90.41% higher than HDPE. Flexural strength and moduli are also found to be the highest for FGNC‐2, 28.57%, and 26.83% higher than HDPE. The highest specific moduli and strength are found for FGNC‐2, 46.16% and 44.14% higher than HDPE, respectively. Experimental findings are found to be strongly in agreement with numerical findings. 3D‐printed FGNC‐2 demonstrated the best flexural and tensile characteristics with the lowest weight and hence can be used to make practical parts and structures that need variable stiffness.Highlights FGNCs functionally graded n anocomposites are concurrently 3D printed. FGNC‐2 exhibited the highest weight saving potential of 12%. FGNC‐2 showed 90.41% and 37.12% enhanced tensile modulus and strength. FGNC‐2 displayed 28.57% and 26.83% improved flexural strength and modulus. FGNCs exhibited better mechanical performance than the homogeneous NCs.