Electromagnetic and thermal properties of a non-conventional polymer nanocomposite based on thermoplastic Polylactic acid (PLA, Ingeo™) filled, in different weight percentage, with multi-walled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), as well as a mixture of both fillers (MWCNTs/GNPs), are analyzed. The combination of notable electrical, thermal, and electromagnetic (EM) properties of the carbon fillers, in concentrations above the percolation threshold, together with the good processability of the PLA matrix gives rise to innovative filaments for 3D printing. In particular, the shielding efficiency (SE) in the frequency range 26–37 GHz of samples increases from 0.20 dB of unfilled PLA up to 13.4 dB for composites containing MWCNTs and GNPs, corresponding to 4% and 95% of SE, respectively. The thermal conductivity of the PLA loaded with 12 wt % of GNPs is 263% higher than that of the unfilled polymer, whereas an improvement of about 99% and 190% is detected for the PLA matrix loaded with MWCNTs and both fillers, respectively. The EM and thermal characterization is combined with a morphological investigation allowing us to correlate the dispersion states of the fillers within the polymer matrix with the observed EM and thermal properties. The EM and thermal characteristics exhibited by the nanocomposites make them suitable for packaging applications of electronic devices with electromagnetic interference (EMI) shielding and thermal dissipation features.

The limitation of poor mechanical stability and difficulties in printing electrically conductive components can be overcome owing to the recent introduction of nanotechnology into the field of additive manufacturing (AM) and the consequent development of nonconventional polymer nanocomposites suitable for 3D printing. In the present work, different weight percentages (up to 6 wt % in total) of carbon-based nanostructures—multiwalled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), and a combination of both fillers (MWCNTs/GNPs)—were incorporated into poly(lactic) acid (PLA, Ingeo™) in an attempt to overcome several limitations of conventional 3D manufacturing based on insulating materials. Solution blending and melt mixing were the two fabrication methods adopted for preparation of the samples under test. A comparison of the morphological, rheological, and electrical properties of the resulting nanocomposites was carried out. Moreover, for the same weight concentrations, the influence of physical and geometrical features (i.e., functionalization and aspect ratio) of the embedded fillers was also investigated. Rheological methods were applied to control the quality of fillers dispersion in PLA matrix. The rheological percolation threshold was considered as reference in order to evaluate the internal structure of nanodispersions. TEM visualization, combined with rheological characterizations, was used for efficient control of the nanofiller dispersion. DC characterization revealed that lower electrical percolation thresholds and higher values of electrical conductivity were achieved using fillers with a larger aspect ratio and melt mixing, respectively. Moreover, given the possibility of obtaining complex and appropriate shapes for electromagnetic compatibility (EC) applications, electromagnetic (EM) response of the nanocomposites at the highest filler concentration was investigated in GHz and THz regions. It was found that the electromagnetic shielding efficiency (EMI) of nanocomposites strongly depended on the aspect ratio of the nanofillers, whereas the type of processing technique did not have a significant effect. Therefore, a careful choice of methods and materials must be made to address the final application for which these materials and further 3D printed architectures are designed.

The electromagnetic properties of composite materials based on poly(lactic) acid (PLA) filled with graphite nanoplatelets (GNP) were investigated in the microwave (26–37 GHz) and terahertz (0.2–1 THz) frequency ranges. The maximum of the imaginary part of the dielectric permittivity was observed close to 0.6 THz for composites with 1.5 and 3 wt.% of GNP. The experimental data of complex dielectric permittivity of GNP/PLA composites was modelled using the Maxwell-Garnett theory. The effects of fine dispersion, agglomeration, and percolation in GNP-based composites on its electromagnetic constitutive parameters, presence, and position of THz absorption peak are discussed on the basis of the modeling results and experimental data. The unique combination of conductive and geometrical parameters of GNP embedded into the PLA matrix below the percolation threshold allow us to obtain the THz-absorptive material, which may be effectively used as a 3D-printing filament.

The microwave-absorbing properties of a heterostructure consisting of an ordered monolayer of porous glassy carbon spheres were experimentally and theoretically investigated in the Ka-band (26–37 GHz) frequency range. The electromagnetic response of such a “moth-eye”-like all-carbon metasurface at a normal incidence angle was modelled on the basis of long-wave approximation. Modelling parameters in the Ka-band were used to estimate and predict the absorption properties of monolayers in free space in the range 1–40 GHz. Experimental and theoretical results demonstrate that a metasurface based on porous glassy carbon spheres is an inert, lightweight, compact, and perfectly absorbing material for designing new effective microwave absorbers in various practically used frequency ranges.

The dielectric properties of epoxy/MWCNT (multi-walled carbon nanotubes)/MgO hybrid composites with a fixed MWCNT amount of 0.12 vol.% (0.2 wt.%) and varying MgO concentrations up to 3 vol.% were investigated in broad frequency (20–40 GHz) and temperature (20–500 K) ranges. The composites with up to 2 vol.% MgO nanoparticles concentration showed a significant increase of DC conductivity in relation to their non MgO-containing counterparts. The optimal content of MgO was found, i.e., 0.46 vol.%, which gave up to 2.5 orders of magnitude larger DC conductivity than those of the samples prepared without MgO additives. Using various amounts of MgO, it is possible to predictably vary the broadband electromagnetic properties of the composites, even entirely eliminating the electrical percolation. Electrical transport at different temperatures can be substantially controlled by the addition of given amounts of MgO. The broadband properties are discussed in terms of the distribution of relaxation times, which are proven to be an effective, noninvasive, and simple tool for checking composite fabrication issues, such as the distribution of MWCNT aggregates within the epoxy matrix.