Phase-change materials (PCMs) can be used to develop thermal energy storage systems as they absorb large amount of latent heat nearly at a constant temperature when changing phase from a solid to a liquid. To prevent leakage when in a liquid state, PCM is shape stabilized in a polymer matrix of high-density polyethylene (HDPE). The present research explores the injection-molded mechanical and thermal properties of different PCM/HDPE composite ratios. The tensile strength and modulus of elasticity at room temperature and with the PCM fully melted within the composite are measured. Additionally, the hardness, latent heat of fusion, phase-change temperature, and thermal conductivity are investigated. An analysis of microstructures of the composite is used to support the findings. The PCM within the PCM/HDPE composite gives it the benefit of thermal storage but causes a decrease in mechanical properties.

Current additive manufacturing (AM) techniques and methods, such as liquid-crystal display (LCD) vat photopolymerization, offer a wide variety of surface-sensing solutions, but customizable internal sensing is both scarce in presence and narrow in scope. In this work, a fabrication process for novel customizable embedded ceramic temperature sensors is investigated. The fabrication techniques and materials are evaluated, followed by extensive characterization via spectral analysis and thermomechanical testing. The findings indicate that LCD-manufactured ceramic sensors exhibit promising sensing properties, including strong linear thermal sensitivity of 0.23% per °C, with an R² of at least 0.97, and mechanical strength, with a hardness of 570 HV, making them suitable for adverse environmental conditions. This research not only advances the field of AM for sensor development but also highlights the potential of LCD technology in rapidly producing reliable and efficient ceramic temperature sensors.