Fused Filament Fabrication of Polyethylene/Graphene Composites for In-Space Manufacturing

Susanna Laurenzi; Federica Zaccardi; Elisa Toto; Maria Gabriella Santonicola; Sabina Botti; Tanya Scalia

doi:10.3390/ma17081888

Fused Filament Fabrication of Polyethylene/Graphene Composites for In-Space Manufacturing

Materials (Basel). 2024 Apr 19;17(8):1888. doi: 10.3390/ma17081888.

Authors

Susanna Laurenzi¹, Federica Zaccardi¹, Elisa Toto², Maria Gabriella Santonicola², Sabina Botti³, Tanya Scalia⁴

Affiliations

¹ Department of Astronautical Electrical and Energy Engineering, Sapienza University of Rome, Via Salaria 851-881, 00138 Rome, Italy.
² Department of Chemical Engineering Materials Environment, Sapienza University of Rome, Via del Castro Laurenziano 7, 00161 Rome, Italy.
³ Photonics Micro- and Nano-Structures Laboratory, Division of Physical Technologies and Security, Nuclear Department, ENEA C.R. Frascati, Via E. Fermi 45, 00044 Frascati, Italy.
⁴ Italian Space Agency, Via del Politecnico s.n.c., 00133 Rome, Italy.

Abstract

Graphene-based composite materials are highly sought after for space applications due to their ability to encompass various properties, such as electrical conductivity, thermal resistance, and radiation shielding. This versatility allows for the creation of multifunctional components that can serve various purposes in space. Three-dimensional (3D) printing of composite materials in space offers a versatile and efficient means of manufacturing components, tools, and structures that are tailored to the unique challenges and requirements of space missions. In this work, we aim to develop 3D-printed composites made of medium-density polyethylene (MDPE) matrix and exfoliated graphene nanoplatelets (xGnP) as filler, using fused filament fabrication (FFF). Our research focuses on the challenges associated with the FFF process for fabricating MDPE/xGnP materials, particularly by optimizing filament extrusion and assessing the resulting material properties and space environmental compatibility. Firstly, we optimize the extrusion process, and use the MDPE/xGnP filaments to fabricate 3D-printed samples after defining the FFF parameters. We employ differential scanning calorimetry (DSC) to assess the melting properties and crystallization degree of the extruded filaments and 3D-printed samples, providing insights into the relationship between these properties and the characteristics of the initial powders. Electrical and tensile tests are carried out to evaluate the material properties after successfully mitigating challenges, such as warping and inadequate adhesion, to build plates during the printing process. Finally, we subject the 3D-printed composites to outgassing tests under exposure to the AM0 solar spectrum to evaluate their space environmental suitability. The results of this work demonstrate the capability of the FFF-based process to efficiently manufacture components made of MDPE/xGnP composites, providing optimized parameters for their potential in-space fabrication.

Keywords: 3D printing; composites; graphene; polyethylene; space environment.

Grants and funding

RG1221816C43DA9B/Sapienza University of Rome