In the present work, Graphite nanoPlatelets/Polyamide‐12 (GnPs/PA‐12) particle composites were produced through additive manufacturing (AM). The selective laser sintering (SLS) technology was used to manufacture 3D‐printed composite components by means of a powder mix of GnPs and PA‐12. The analyzed combination of technology and materials allows to obtain parts with improved thermal, electrical, and tribological properties, while maintaining a low production cost. In total were realized 5 different scenarios, each one with a different wt% of the GnPs reinforcement (2‐4‐6‐8‐10 wt%), and compared the results to the PA‐12 matrix. Experimental tests were performed to study the morphology (profilometry, SEM, wettability), the electrical conductivity under different normal loads (0.1–1 kN), the thermal performance, and the tribological properties of each sample. The results show that the increase of GnPs particles dispersed in the matrix leads to a hydrophobic behavior of the surface. An improvement in electrical conductivity (from 10⁻¹¹ S/cm of the pure PA‐12 matrix to 10⁻⁴ S/cm of the 10 wt% GnPs) and thermal performance (33,6% improvement for the best‐case scenario compared to the bare matrix) was observed. Tribological tests underlined a reduction of 25% in friction coefficient and an improvement of 80% in wear resistance compared to the PA‐12 matrix.Highlights: 3D printed GnPs/PA‐12 composites does not exhibit any significant geometrical alteration. GnPs enable hydrophobic surfaces with increased contact angles. Electrical conductivity improved from 10⁻¹¹ S/cm of the unfilled PA‐12 matrix up to 10⁻⁴ S/cm, for the 10 wt% GnPs sample. Thermal performance improves up to 33.6% with GnPs reinforcement. 10 wt% GnPs reduces friction by 25% and wear by 81%.

Considering the importance of the automotive industry, reducing the environmental impact of automotive component manufacturing is crucial. Additionally, lightening of the latter promotes a reduction in fuel consumption throughout the vehicle’s life cycle, limiting emissions. This study presents a comprehensive approach to optimizing and manufacturing a MacPherson steering knuckle using topology optimization (TO), additive manufacturing, and rapid investment casting (RIC). Static structural simulations confirmed the mechanical integrity of the optimized design, with stress and strain values remaining within the elastic limits of the SG A536 iron alloy. The TO process achieved a 30% reduction in mass, resulting in lower material use and production costs. Additive manufacturing of optimized geometry reduced resin consumption by 27% and printing time by 9%. RIC simulations validated efficient mold filling and solidification, with porosity confined to removable riser regions. Life cycle assessment (LCA) demonstrated a 27% reduction in manufacturing environmental impact and a 31% decrease throughout the component life cycle, largely due to vehicle lightweighting. The findings highlight the potential of integrated TO and advanced manufacturing techniques to produce structurally efficient and environmentally sustainable automotive components. This workflow offers promising implications for broader industrial applications that aim to balance mechanical performance with ecological responsibility.

Copper, though highly conductive, requires improved wear resistance and thermal dissipation in applications that involve continuous movement and current-induced vibrations, such as power breakers. Conventional solutions, such as copper–tungsten alloys or lubricant use, face limitations in durability, friction, or environmental impact. This study explores the development of copper–graphene (Cu-GNPs) composite coatings using pulsed electrodeposition to enhance the tribological, thermal, and mechanical properties of circuit breaker components by adopting an industrially scalable technique. The influence of deposition bath temperature, duty cycle, and frequency on coating morphology, hardness, wear resistance, and heat dissipation was systematically evaluated using a 2³ full factorial design and an Analysis of Variance (ANOVA). The results revealed that optimized pulsed electrodeposition significantly improved coating performance: hardness increased by 76%, wear volume decreased by more than 99%, and friction coefficient stabilized at 0.2, reflecting effective graphene integration. The addition of graphene further improved thermal diffusivity by 19.5%, supporting superior heat dissipation. These findings suggest that pulsed copper–graphene composite coatings offer a promising alternative to traditional copper alloys, enhancing the lifespan and reliability of electronic components through improved wear resistance, lower friction, and superior heat transfer.