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NASA NTRS1991

Preliminary properties of a resin from ethynyl terminated materials

A blend composed of an ethynyl terminated aspartimide (brittle component) and an ethynyl terminated arylene ether oligomer (tough component) was thermally cured to yield a resin which underwent preliminary evaluation to determine the potential for use in structural applications on aerospace vehicles. The blend exhibited good compression moldability, allowing for fabrication of neat moldings, adhesive specimens and composites at temperatures of 250 C under a pressure of 1.4 MPa (200 psi). Neat resin moldings and adhesive specimens provided relatively high mechanical properties. Composite specimens provided promising results in spite of fiber misalignment, fiber washout, and a small amount of panel warpage.

Hergenrother, Paul M.↗

NASA NTRS1993

Fatigue-life behavior and matrix fatigue crack spacing in unnotched SCS-6/Timetal 21S metal matrix composites

Fatigue tests of the SCS-6/Timetal 21S composite system were performed to characterize the fatigue behavior for unnotched conditions. The stress-life behavior of the unnotched (9/90)2s laminates was investigated for stress ratios of R = 0.1 and R = 0.3. The occurrence of matrix cracking was also examined in these specimens. This revealed multiple matrix crack initiation sites throughout the composite, as well as evenly spaced surface cracks along the length of the specimens. No difference in fatigue lives were observed for stress ratios of R = 0.1 and R = 0.3 when compared on a stress range basis. The unnotched SCS-6/Timetal 21S composites had shorter fatigue lives than the SCS-6/Ti-15-3 composites, however the neat Timetal 21S matrix material had a longer fatigue life than the neat Ti-15-3.

Ward, G. T.↗

NASA NTRS1994

Poly(arylene ether imidazole) surfacing films for flat and parabolic structures

Films of thermoplastic poly(arylene ether imidazole)s (PAEIs) are used as surface modifiers for neat resin panels and composite resin panels. The PAEI polymer contains imidazole groups along the backbone which co-cure, i.e., react chemically, with epoxies or bismaleimides during processing and thereby provide excellent adhesion between the PAEI film and an epoxy or bismaleimide neat resin or composite resin facesheet. The film provides good adhesion and a smooth surface to the finished part and acts as a release agent from the mold. The as-processed integral structures have very smooth (specular) surfaces, and since the film releases readily from a glass mold, no release agent is necessary. The PAEI film is thermally stable, resistant to electron radiation, and adheres tenaciously to the facesheet. The film maintains good adhesion even after thermal cycling from room temperature to approximately -196 C.

Connell, John W.↗

NASA NTRS1996

High Temperature Degradation Mechanisms in Polymer Matrix Composites

Polymer matrix composites are increasingly used in demanding structural applications in which they may be exposed to harsh environments. The durability of such materials is a major concern, potentially limiting both the integrity of the structures and their useful lifetimes. The goal of the current investigation is to develop a mechanism-based model of the chemical degradation which occurs, such that given the external chemical environment and temperatures throughout the laminate, laminate geometry, and ply and/or constituent material properties, we can calculate the concentration of diffusing substances and extent of chemical degradation as functions of time and position throughout the laminate. This objective is met through the development and use of analytical models, coupled to an analysis-driven experimental program which offers both quantitative and qualitative information on the degradation mechanism. Preliminary analyses using a coupled diffusion/reaction model are used to gain insight into the physics of the degradation mechanisms and to identify crucial material parameters. An experimental program is defined based on the results of the preliminary analysis which allows the determination of the necessary material coefficients. Thermogravimetric analyses are carried out in nitrogen, air, and oxygen to provide quantitative information on thermal and oxidative reactions. Powdered samples are used to eliminate diffusion effects. Tests in both inert and oxidative environments allow the separation of thermal and oxidative contributions to specimen mass loss. The concentration dependency of the oxidative reactions is determined from the tests in pure oxygen. Short term isothermal tests at different temperatures are carried out on neat resin and unidirectional macroscopic specimens to identify diffusion effects. Mass loss, specimen shrinkage, the formation of degraded surface layers and surface cracking are recorded as functions of exposure time. Geometry effects in the neat resin, and anisotropic diffusion effects in the composites, are identified through the use of specimens with different aspect ratios. The data is used with the model to determine reaction coefficients and effective diffusion coefficients. The empirical and analytical correlations confirm the preliminary model results which suggest that mass loss at lower temperatures is dominated by oxidative reactions and that these reaction are limited by diffusion of oxygen from the surface. The mechanism-based model is able to successfully capture the basic physics of the degradation phenomena under a wide range of test conditions. The analysis-based test design is successful in separating out oxidative, thermal, and diffusion effects to allow the determination of material coefficients. This success confirms the basic picture of the process; however, a more complete understanding of some aspects of the physics are required before truly predictive capability can be achieved.

Cunningham, Ronan A.↗

NASA NTRS1997

High Temperature Degradation Mechanisms in Polymer Matrix Composites

Polymer matrix composites are increasingly used in demanding structural applications in which they may be exposed to harsh environments. The durability of such materials is a major concern, potentially limiting both the integrity of the structures and their useful lifetimes. The goal of the current investigation is to develop a mechanism-based model of the chemical degradation which occurs, such that given the external chemical environment and temperatures throughout the laminate, laminate geometry, and ply and/or constituent material properties, we can calculate the concentration of diffusing substances and extent of chemical degradation as functions of time and position throughout the laminate. This objective is met through the development and use of analytical models, coupled to an analysis-driven experimental program which offers both quantitative and qualitative information on the degradation mechanism. Preliminary analyses using coupled diffusion/reaction model are used to gain insight into the physics of the degradation mechanisms and to identify crucial material parameters. An experimental program is defined based on the results of the preliminary analysis which allows the determination of the necessary material coefficients. Thermogravimetric analyses are carried out in nitrogen, air, and oxygen to provide quantitative information on thermal and oxidative reactions. Powdered samples are used to eliminate diffusion effects. Tests in both inert and oxidative environments allow the separation of thermal and oxidative contributions to specimen mass loss. The concentration dependency of the oxidative reactions is determined from the tests in pure oxygen. Short term isothermal tests at different temperatures are carried out on neat resin and unidirectional macroscopic specimens to identify diffusion effects. Mass loss, specimen shrinkage, the formation of degraded surface layers and surface cracking are recorded as functions of exposure time. Geometry effects in the neat resin, and anisotropic diffusion effects in the composites, are identified through the use of specimens with different aspect ratios. The data is used with the model to determine reaction coefficients and effective diffusion coefficients. The empirical and analytical correlations confirm the preliminary model results which suggest that mass loss at lower temperatures is dominated by oxidative reactions and that these reaction are limited by diffusion of oxygen from the surface. The mechanism-based model is able to successfully capture the basic physics of the degradation phenomena under a wide range of test conditions. The analysis-based test design is successful in separating out oxidative, thermal, and diffusion effects to allow the determination of material coefficients. This success confirms the basic picture of the process; however, a more complete understanding of some aspects of the physics are required before truly predictive capability can be achieved.

Cunningham, Ronan A.↗

NASA NTRS1998

Phenylethynyl Containing Polyarylene Ethers/Polyimides Resin Infiltration of Composites

The following tasks were performed at NCA&TSU during the second year in performance of the grant. LaRC-LV-1 13 resin was synthesized at NCA&TSU. In order to perform the synthesis, glassware and needed apparatus were purchased with grant funds along with the appropriate monomers. It was found that the LaRC-LV-1 13 resin was easily synthesized by the NMP solvent/toluene imminization/distilled water precipitation process. However, in use this resin exhibited a bubbling/foaming behavior during cure that was detrimental leading to the production of composite panels having a high void content. Composite panels were fabricated using compression molding and resin transfer molding (RTM) techniques. Initial fiber volume determinations were computed at NCA&TSU along with NASA-Langley measured c-scans on the panels produced. The initial results indicated a unsatisfactory level of approximately 20% by volume of voids. Testing of uniaxial coupons in compression to failure also agreed with these results. The uniaxial coupons delaminated as the major mode of failure indicative of an unacceptably low level of resin and to much void content in the final composites produced. In discussions with Dr. Brian Jensen, it was suggested the void fraction needs to be reduced to at least 2% by volume for a useful composite. The panels produced used both resin synthesized at NASA-Langley and NCA&TSU. In reviewing our progress over the past year, it was noted that the resin as formulated by the current synthesis process bubbled at elevated temperature. This was especially observed in neat resin slugs cured at the recommended one, four and eight hour cure temperatures. Pressurized cures where then performed with pressures up to 200 psi and simultaneously the lowest eight hour cure temperatures. Although this procedure reduced the amount of bubbles to some extent in the neat resin slugs it did not completely eliminate them. The cure reaction appears to be very energetic even at the lowest recommended cure temperature. Currently, the pressurized cure apparatus developed at NCA&TSU is limited to 200 psi.

Dunn, DeRome O.↗

NASA NTRS2001

Longtime Durability of PMR-15 Matrix Polymer at 204, 260, 288, and 316 C

Isothermal weight loss studies at the Glenn (Lewis) Research Center were conducted at four temperatures (204, 260, 288, and 316 C) with specimens of varied geometric shapes to investigate the mechanisms involved in the thermal degradation of PMR-15. Both neat resin behavior and composite behaviors were studied. Two points of interest in these studies are the role(s) of oxygen in the mechanisms involved in the thermo-oxidative degradation of these composite materials and the dimensional changes that occur during their useable lifetime. Specimen dimensional changes and surface layer growth were measured and recorded. It was shown that physical and chemical changes take place as a function of time and location in PMR-15 neat resin and composites as aging takes place in air at elevated temperatures. These changes initiate at the outer surfaces of both materials and progress inward following the oxygen as it proceeds by diffusion into the central core of each material. Microstructural changes cause changes in density, material shrinkage (strains), glass transition temperature, dimension, dynamic shear modulus, and compression properties. These changes also occur slowly dividing the polymer material into two distinct parts: a visibly undamaged core section between two visibly damaged surface layers. The surface layer has a significant effect on compression properties of thinner specimens, but the visibly undamaged core material controls these properties for specimens having eight or more plies. It was demonstrated that there are three different mechanisms involved in the degradation of PMR-15 during aging at elevated temperatures. These are a weight gain, a small weight fraction bulk material weight loss, and a large mass fraction weight loss concentrated at the surface of the polymer or composite. At the higher temperatures (260 C and above), the surface loss predominates. Below 260 C, the surface loss and the bulk core loss become more equivalent. Between 175 and 260 C, the initial weight change is due to a weight gain mechanism with a visible lifetime that diminishes as the aging temperature increases.

Bowles, Kenneth J.↗

NASA NTRS2002

Viscoelastic and Mechanical Properties of Thermoset PMR-type Polyimide-Clay Nanocomposites

High temperature thermoset polyimide-clay nanocomposites were prepared by blending 2.5 and 5 wt% of an unmodified Na(+-) montmorillonite (PGV) and two organically modified FGV (PGVCl0COOH, PGVC12) with a methanol solution of PMR-15 precursor. The methanol facilitated the dispersal of the unmodified clay. Dynamic mechanical analysis results showed a significant increase in the thermomechanical properties (E' and E") of 2.5 wt% clay loaded nanocomposites in comparison with the neat polyimide. Higher glass transition temperatures were observed for 2.5 wt% nanocomposites compared to the neat polyimide. Flexural properties measurements for the 2.5 wt% nanocomposites showed a significant improvement in the modulus and strength, with no loss in elongation. This trend was not observed for the 5 wt% nanocomposites. An improvement in the CTE was observed for the PGV/PMR-15 nanocomposites, while a decrease was observed for the organically modified samples. This was attributed to potential variations in the interface caused by modifier degradation.

Abdalla, Mohamed O.↗

NASA NTRS2003

Structural Evolution and Mechanical Properties of PMR-15/Layered Silicate Nanocomposites

In the first year of this research, we successfully synthesized and characterized Polymer/ Layered Silicate nanocomposite using the polyimide PMR-15 as the polymer and several layered silicate nanoparticles. We have scaled up the process to allow fabrication of monoliths using these nanocomposites. The morphology of these systems was found to evolve during processing to an exfoliated structure for one system and intercalated for the rest. Correlation with Transmission Electron Microscopy studies is underway. Dynamic mechanical analysis (DMA) results showed a significant increase in the thermomechanical properties (E' and E'') of 2.5 wt.% clay loaded nanocomposites in comparison to the neat polyimide. Increasing the clay loading to 5 wt.% decreased these properties. Higher glass transition temperatures were observed for 2.5 wt.% nanocomposites compared to the neat polyimide. A lower coefficient of thermal expansion was observed only for the PGV/PMR-15 nanocomposite. An improvement in the flexural properties (modulus, strength and elongation) was observed for the 2.5 wt.% nanocomposite but not for the 5 wt.% nanocomposites. The improved barrier properties polymer/ silicate nanocomposites suggest that moisture uptake should be decreased for PMR-15 nanocomposites. The results of some recent experiments to examine delineate the ability of the silicate nanoparticles in improving the hydrolytic degradation of PMR-15 will be discussed.

Campbell, Sandi↗

NASA NTRS2005

1024 x 1024 pixel mid-wavelength and long-wavelength infrared QWIP focal plane arrays for imaging applications

Mid-wavelength infrared (MWIR) and long-wavelength infrared (LWIR) 10(24) x 10(24) pixel quantum well infrared photodetector (QWIP) focal planes have been demonstrated with excellent imaging performance. The MWIR QWIP detector array has demonstrated a noise equivalent differential temperature (NEAT) of 17 mK at a 95 K operating temperature with f/2.5 optics at 300 K background and the LWIR detector array has demonstrated a NEAT of 13 mK at a 70 K operating temperature with the same optical and background conditions as the MWIR detector array after the subtraction of system noise. Both MWIR and LWIR focal planes have shown background limited performance (BLIP) at 90 K and 70 K operating temperatures respectively, with similar optical and background conditions. In this paper, we will discuss the performance in terms of quantum efficiency, NE(delta)T, uniformity, operability and modulation transfer functions.

uniformity↗

NASA NTRS1996

Poly(arylene ether imidazole) surfacing films for flat and parabolic structures

Films of thermoplastic poly(arylene ether imidazole)s (PAEI)s are used as surface modifiers for neat resin panels and composite resin panels. The PAEI polymer contains imidazole groups along the backbone which co-cure, i.e., react chemically, with epoxies or bismaleimides during processing and thereby provide excellent adhesion between the PAEI film and an epoxy or bismaleimide neat resin or composite resin facesheet. The film provides good adhesion and a smooth surface to the finished part and acts as a release agent from the mold. The as-processed integral structures have very smooth (specular) surfaces, and since the film releases readily from a glass mold, no release agent is necessary. The PAEI film is thermally stable, resistant to electron radiation, and adheres tenaciously to the facesheet. The film maintains good adhesion even after thermal cycling from room temperature to .about. -196.degree. C.

Connell, John W.↗

NASA NTRS2010

Out-Life Characteristics of IM7/977-3 Composites

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-time limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-time limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The effects of room temperature aging on the thermal and visco-elastic properties of the materials were investigated. Neat resin was evaluated by differential scanning calorimetry to characterize thermal properties and change in activation energy of cure. Neat resin was also evaluated by rheometry to characterize its processability in composite fabrication. IM7/977-3 prepreg was evaluated by dynamic mechanical analysis to characterize the curing behavior. Prepreg tack was also evaluated over 60 days. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Miller, Sandi G.↗

NASA NTRS2011

Safe, in situ methodologies for the destruction of triacetone triperoxide and other explosive peroxides

Triacetone triperoxide (TATP) and other explosives of the peroxide family are safely degraded in situ. Nano and micron size metal particles in an elemental state include pure iron and magnesium or iron and magnesium particles that are mechanically alloyed with palladium and nickel. The metal particles are used in both the elemental state and in emulsions that are made from water, a hydrophobic solvent, such as corn oil, and a food-grade nonionic surfactant. The neat metals and emulsified zero valent metals (EZVM) safely degrade TATP with the major degradation product being acetone. The EZVM system absorbs and dissolves the TATP into the emulsion droplets where TATP degradation occurs. EZVM systems are ideal for degrading dry TATP crystals that may be present on a carpet or door entrance. Both the neat metal system and the emulsion system (EZVM) degrade TATP in an aqueous slurry.

Clausen, III, Christian↗

NASA NTRS2016

Pick and Eat Crop Testing: Dwarf Tomato and Pepper as Candidate Space Crops

Several dwarf tomato and pepper varieties were evaluated under International Space Station (ISS)-simulated growth conditions (22 degrees Centigrade, 50 percent relative humidity, 1500 parts per million CO2, and 300 micromoles per square meter per second of light for 16 hours per day) with the goal of selecting those with the best growth, nutrition, and organoleptic potential for use in a pick and eat salad crop system on ISS and future exploration flights. Testing included six cultivars of tomato (Red Robin, Scarlet Sweet 'N' Neat, Tiny Tim, Mohamed, Patio Princess, and Tumbler) and six cultivars of pepper (Red Skin, Fruit Basket, Cajun Belle, Chablis, Sweet Pickle, and Pompeii). Plants were grown to an age sufficient to produce fruit (up to 106 days for tomato and 109 days for pepper) using Turface (arcillite) potting media with 18-6-8 control-release fertilizer and supplemental nutrient solution beginning around 60-days-age. Tomato fruits were harvested when they showed full red color, beginning around 70-days age and then at weekly intervals thereafter, while peppers were grown until fruits showed color and were harvested twice (first test) and just once at the end of the second test, with the final harvests including colored and green fruit. Plant sizes, yields, and nutritional attributes were measured and used to down-select to three cultivars for each species. In particular, we were interested in cultivars that were short (dwarf) but still produced high yields. Nutritional data included elemental (Ca, Mg, Fe, and K) content, vitamin K, phenolics, lycopene (for tomato), anthocyanin, lutein, and zeaxanthin. The three down-selected cultivars for each species were grown again and the harvested fruit sent to NASA's Johnson Space Center for sensory evaluation, which included overall acceptability, appearance, color intensity, aroma, flavor and texture. The combined data were compared and given weighting factors to rank the cultivars as candidates for testing in space. Weightings gave maximum importance to plant size (smaller being good) and fruit yield (greater yields being good). For tomato, the ranking was 1) cultivar Mohamed and cultivar Red Robin (tied), and 3) cultivar Sweet N' Neat. For pepper, the ranking was 1) cultivar Pompeii, 2) cultivar Red Skin, and 3) cultivar Fruit Basket. These rankings are somewhat subjective but provide a starting point for conducting higher fidelity testing with these crops (e.g., testing with light emitting diode lighting similar to the Veggie plant unit on ISS), and ultimately conducting a flight experiment.

Food↗

NASA NTRS2018

Turbo-Generation Control

Electrified Aircraft Propulsion (EAP) power systems are being studied at the NASA Electric Aircraft Testbed (NEAT) facility. The electric motors at NEAT have the capability to dynamically respond to commands that would be unrealistic when integrated with turbomachinery. There is a need to provide more realistic turbine transients for future system performance studies.

Hybrid Electric↗

NASA NTRS2016

Computational and Experimental Study of Li-doped Ionic Liquids at Electrified Interfaces

We evaluate the influence of Li-salt doping on the dynamics, capacitance, and structure of three ionic liquid electrolytes, [pyr14][TFSI], [pyr13][FSI], and [EMIM][BF4], using molecular dynamics and polarizable force fields. In this respect, our focus is on the properties of the electric double layer (EDL) formed by the electrolytes at the electrode surface as a function of surface potential (Psi). The rates of EDL formation are found to be on the order of hundreds of picoseconds and only slightly influenced by the addition of Li-salt. The EDLs of three electrolytes are shown to have different energy storage capacities, which we relate to the EDL formation free energy. The differential capacitance obtained from our computations exhibits asymmetry about the potential of zero charge and is consistent with the camel-like profiles noted from mean field theories and experiments on metallic electrodes. The introduction of Li-salt reduces the noted asymmetry in the differential capacitance profile. Complementary experimental capacitance measurements have been made on our three electrolytes in their neat forms and with Li-salt. The measurements, performed on glassy carbon electrodes, produce U-like profiles, and Li-salt doping is shown to strongly affect capacitance at high magnitudes of Psi. Differences in the theoretical and experimental shapes and magnitudes of capacitance are rationalized in terms of the electrode surface and pseudocapacitive effects. In both neat and Li-doped liquids, the details of the computational capacitance profile are well described by Psi-induced changes in the density and molecular orientation of ions in the molecular layer closest to the electrode. Our results suggest that the addition of Li+ induces disorder in the EDL, which originates from the strong binding of anions to Li+. An in-depth analysis of the distribution of Li+ in the EDL reveals that it does not readily enter the molecular layer at the electrode surface, preferring instead to be localized farther away from the surface in the second molecular layer. This behavior is validated through an analysis of the free energy of Li+ solvation as a function of distance from the electrode. Free energy wells are found to coincide with localized concentrations of Li+, the depths of which increase with Psi and suggest a source of impedance for Li+ to reach the electrode.

Haskins, Justin B.↗

NASA NTRS2019

Dwarf Tomato and Pepper Cultivars for Space Crops

Several dwarf tomato and pepper varieties were evaluated under ISS-simulated growth conditions (22ºC, 50% RH, 1500 ppm CO2, and 300 μmol m(exp -2) s(exp -1) of light for 16 h per day) with the goal of selecting those with the best growth, nutrition, and organoleptic potential for use in a pick and eat salad crop system on ISS and future exploration flights. Testing included six cultivars of tomato (Red Robin, Scarlet Sweet ’N’ Neat, Tiny Tim, Mohamed, Patio Princess, and Tumbler) and six cultivars of pepper (Red Skin, Fruit Basket, Cajun Belle, Chablis, Sweet Pickle, and Pompeii). Plants were grown to an age sufficient to produce fruit (70 to 106 days for tomato and 109 days for pepper). Tomato fruits were harvested when they showed full red color, beginning ca. 70-days age and then at weekly intervals thereafter, while peppers were grown until numerous fruits showed color and all fruits (green and colored) were harvested once at the end of the test. Plant sizes, yields, and nutritional attributes were measured and used to down-select to three cultivars for each species. In particular, we were interested in cultivars that were short (dwarf) but still produced high yields. Nutritional data included elemental (Ca, Mg, Fe, and K) composition, vitamin K, phenolics, lycopene, anthocyanin, lutein, and zeaxanthin. The three down-selected cultivars for each species were evaluated for sensory attributes, including overall acceptability, appearance, color intensity aroma, flavor and texture. The combined data were compared and given weighting factors to rank the cultivars as potential candidates for testing in space. For tomato, the ranking was 1) cv. Mohamed, 2) cv. Red Robin, and 3) cv. Sweet N’ Neat. For pepper, the ranking was 1) cv. Pompeii, 2) cv. Red Skin, and 3) cv. Fruit Basket. These rankings are somewhat subjective but provide a good starting point for conducting higher fidelity testing with these crops (e.g., testing with LED lighting similar to the Veggie plant unit), and ultimately conducting flight experiments.

Spencer, LaShelle E.↗

NASA NTRS2026

Electromagnetic Melt Processing: A Pathway to New Additive Manufacturing Technologies for Functional High-Performance Thermoplastics

In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.

Powder bed fusion↗