Variable orientation in material extrusion of short carbon fiber reinforced polymer composites with high thermal conductivity

Controllable orientation architecture possesses tunable thermal behavior for effective heat dissipation in unidirectional product fields, meanwhile without interference with adjacent components. Herein, we proposed a variable orientation strategy in material extrusion of short carbon fiber (SCF) reinforced polymer composites framework with spatially tunable thermal properties. It was achieved due to the following reasons: (Ⅰ) Inherent shear flow in the nozzle; (Ⅱ) Increasing tensile flow by changing the ratio between the printing speed of monofilament and the feeding speed of filament (Vp/f); (Ⅲ) Further surface tension due to thinning monofilament by varying Vp/f. The SCF with different orientations and content reinforced polyether-ether-ketone (PEEK) composites were successfully fabricated. The microcosmic orientation of SCF could be programmed from a three-layer hierarchical framework to a single-layer oriented framework at different Vp/f. Benefit from variable orientation, the through-plane thermal conductivity of SCF/PEEK composites achieved a thermal conductivity enhancement of 173.9%. In addition, the simulated application of SCF/PEEK composites in the CPU of the computer showed excellent heat transfer during heating. Further, the thermal conductivity mechanism of the synergistic influence between Vp/f and SCF content was analyzed by cross-sectional microstructure. The proposed strategy in this work for fabricating variable orientation of SCF reinforced polymer composites showcases great application prospects in electronic devices and unidirectional product fields.