Conductive Polymer-Based Electronics in Additive Manufacturing: Materials, Processing, and Applications

Conductive polymers are a notable breakthrough in electronic technology, providing distinctive electrical characteristics that render them appropriate for various uses in contemporary products like OLEDs (organic light-emitting diodes), batteries, sensors, and medical equipment. Their use in additive manufacturing (AM) processes represents a significant advancement, allowing for the direct integration of electronic functionality into intricate 3D-printed structures. This results in a reduction in production time and costs associated with conventional assembly methods. This paper examines different conductive polymers, including PANI (polyaniline), PPy (polypyrrole), and PEDOT (poly(3,4-ethylene dioxythiophene)), with a focus on their involvement in AM methods including fused deposition modeling and inkjet printing. Current developments in ink formulations, including those integrating graphene, are improving conductivity while also tackling environmental issues. However, there are still obstacles that need to be overcome, such as finding the right balance between conductivity and processability, maintaining stability in different environmental conditions, dealing with biocompatibility concerns, and optimizing compatibility with other materials. Continuing research is improving these materials, and conductive polymers show potential for transforming electronics and medical applications due to their ability to be scaled up, their flexibility, and their adjustable electronic properties. This review article offers a thorough summary of the latest research trends, difficulties, and future paths in the realm of electronics and AM that utilize conductive polymers.