Advanced 3D Printed Conductive Polymer Nanocomposites toward Electromagnetic Interference Shielding

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Electrical devices inherently radiate electromagnetic waves. Electromagnetic interference (EMI) occurs when radiated electromagnetic waves from a device interfere with its operation or the operation of other electronic devices. Given the proliferation of sensitive electronics in various industries, shielding electromagnetic waves has become a major challenge in a broad spectrum of sectors such as consumer electronics, and the automotive, aerospace, and defense industries. Conductive polymer nanocomposites have been identified as appealing substitutions for currently used metallic shields because of their lightweight, low cost, corrosion resistance, easy processability, and improved design options. However, the field of polymer shields is still in its infancy and suffers three significant challenges. First, the EMI shielding of polymer shields is inferior to that of metals. Second, common molded nanocomposites are limited in their EMI shielding potential due to the lack of control on the electrical properties across molded structures. Third, fabricating complex geometries of polymer shields for advanced applications by common molding techniques requires intricate molds, or needs to go through expensive, exhausting post-processing to give the final shape to polymer nanocomposites. As such, the overarching goal of this research program is to develop the knowledge and technology to generate 3D printed conductive polymer nanocomposites as versatile electromagnetic shields with complex geometries and adjustable EMI shielding mechanisms. The multilayered patterned structures generated through 3D printing would allow manipulating the EMI shielding mechanisms, not possible in common molded nanocomposites. In this regard, I follow three specific objectives: Objective 1: Nanomaterial Synthesis. Synthesize and engineer novel conductive nanomaterials (nanofillers) that are more conductive and feature larger surface area than current conductive fillers; Objective 2: Polymer Processing. Develop and architect the morphology and structure of synthesized nanomaterial/polymer nanocomposites throughout polymer-nanofiller mixing (melt mixing and filament extrusion) and shaping (3D printing of polymer nanocomposite filaments); Objective 3: 3D-Printed Polymer Nanocomposites Development. Understand the relationship between the structure of nanomaterials, the architecture of 3D printed polymer nanocomposites, and EMI shielding properties. 3 PhD will undertake the proposed research program. The trained HQP will obtain expertise and hands-on experience in Nanomaterials Synthesis, Polymer Processing, and 3D Printed Polymer Nanocomposites Development. This research program will help Canada take a position at the forefront of the multi-billion-dollar market of electromagnetic shields. This research program will also contribute to the development of new and improved synthesis technologies for conductive nanomaterials and 3D printed polymer nanocomposites in Canada.