2025 ASEE Annual Conference & Exposition

Material extrusion (MEX) is a well-known additive manufacturing (AM) technique used to create 3D objects by extruding semi-molten thermoplastic materials from a heated nozzle or nozzles onto a platform. This technique is commonly used, and it is a low-cost fabrication solution for several practitioners. Lately, fiber-infused MEX has been gaining popularity due to its advantages in being lightweight and high strength compared to traditional polymers. Adding nanoparticles even makes this process more unique and it is a new direction for several recent AM studies. The study aims to investigate and fulfill critical goal in nano level MEX technology. This study explores the mechanical behavior of components produced by this technology, that focuses on both virgin polymers and those infused with nanoparticles which are Multiwalled Carbon Nanotubes (MWCNTs). A key finding of this study involves formulating the influence of post-processing techniques, such as annealing, vapor smoothing, and different epoxy coatings on mechanical characterizations of the base polymer matrix. Adding a post-processing step like annealing improves the mechanical properties of polymer by reducing internal stresses and enhancing the crystallinity of material, while vapor smoothing refines and improves surface finish by reducing visible layer lines generated during 3D printing, both techniques improve mechanical performance and aesthetic representation of printed parts. This study includes the effects of pre-and post-processing techniques at the micro level and the determination of different carbon weight percentages in composites to maintain agglomeration. Overall, this present research study will contribute to the overall understanding and analysis of the different MEX parameters and also lead to the development of reliable and efficient techniques that enable the production of high-quality printed products with improved dimensional, mechanical, surface and structural integrity. This presentation will report the current findings of the research with the real-world samples post-processed with these three techniques.