LAUSR

Abstract Polymer extrusion three dimensional (3D) printing, such as fused deposition modeling (FDM), has recently garnered attention due to its inherent process flexibility and rapid prototyping capability. Specifically, the addition of electrical components and interconnects into a 3D printing build sequence has received heavy interest for space applications. However, the addition of these components, along with the thermal load associated with space-based applications, may prove problematic for typical thermally insulating 3D printed polymer structures. The work presented here addresses thermally conductive polymer matrix composites (specifically, graphite, carbon fiber, and silver in an acrylonitrile butadiene styrene polymer matrix) to identify the effect of composite geometry and print direction on thermal anisotropic properties. The work also examines the effect of these composites on print quality, mechanical tensile properties, fracture plane analysis, micrograph imaging, and cube satellite thermal analysis. The thermal conductivity of 3D printed material systems in this work may enable the production of thermally stable 3D printed structures, supports, and devices. Key results of this work include anisotropic thermal conductivity for 3D printed structures related to print direction and filler morphology meaning that thermal conductivity can be controlled through a combination of print raster direction and material design. When the materials analyzed in this work are incorporated with other active cooling systems, space-based 3D printed applications can then be designed to incorporate increasing thermal loads, opening a new door to producing space-ready 3D printed structures.