This study explores the potential of novel boron nitride (BN) microplatelet composites with combined thermal conduction and electrical insulation properties. These composites are manufactured through Fusion Deposition Modeling (FDM), and their application for thermal management in electronic devices is demonstrated. The primary focus of this work is, therefore, the investigation of the thermoplastic composite properties to show the 3D printing of lightweight polymeric heat sinks with remarkable thermal performance. By comparing various microfillers, including BN and MgO particles, their effects on material properties and alignment within the polymer matrix during filament fabrication and FDM processing are analyzed. The characterization includes the evaluation of morphology, thermal conductivity, and mechanical and electrical properties. Particularly, a composite with 32 wt% of BN microplatelets shows an in-plane thermal conductivity of 1.97 W m⁻¹ K⁻¹, offering electrical insulation and excellent printability. To assess practical applications, lightweight pin fin heat sinks using these composites are designed and 3D printed. Their thermal performance is evaluated via thermography under different heating conditions. The findings are very promising for an efficient and cost-effective fabrication of thermal devices, which can be obtained through extrusion-based Additive Manufacturing (AM), such as FDM, and exploited as enhanced thermal management solutions in electronic devices.

In the context of circular economy and sustainable production of materials, this project investigated the feasibility of producing sustainable polyhydroxyalkanoates (PHA) from microalgae and sludge used in the treatment of municipal wastewater. The overall process was studied looking at the main steps: microalgae production, fermentation of the biomass, production and characterization of the PHAs. It was possible to obtain blends of hydroxybutyrate-hydroxyvalerate copolymers with high molecular weights and different compositions depending on the nature of the feedstock (mixed volatile fatty acids). In some cases, almost completely amorphous PHA materials were obtained, suggesting a potential diversification of uses and applications.

Polyhydroxyalkanoates are a promising class of biopolymers that can allow the production of sustainable plastic materials. The mechanical properties of such materials are very important for possible industrial applications, but the amount of polymer required for common mechanical testing can be orders of magnitude more than what is possible to achieve with a lab-scale process. Nanoindentation with the Atomic Force Microscope allows an estimation of the Elastic Modulus that can be used as a preliminary measurement on PHA when only a limited amount of material is available. Poly(hydroxybutyrate-co-hydroxyvalerate) copolymers were analyzed, with moduli ranging from 528 ± 62 MPa to 1623 ± 172 MPa, according to both the composition and the crystallization kinetics.

Flexible high‐performance electronics are facing the challenge of managing increasing thermal loads in the latest devices. This study presents a one‐step method for 3D printing flexible boron nitride (BN) polymer composites via vat photopolymerization, enhancing thermal conductivity by 270% to 0.8 W m⁻¹ K⁻¹ and improving dielectric properties (17% lower permittivity and 18% reduced dielectric loss). Unmodified h‐BN microplatelets are integrated in a UV‐curable polymer matrix, simplifying the manufacturing compared to functionalized or hybrid filler systems. Composites with 20 wt% BN achieve feature resolutions of 125 μm with excellent dimensional fidelity, while mechanical properties show an increase in tensile strength of 215% and retain flexibility. The thermal performance of the 3D‐printed structures is assessed using IR thermography under simulated operational conditions, confirming enhanced heat transfer in the BN‐filled structures. Overall, this research presents a practical method for improving thermal management in flexible electronics, offering an easy way to create high‐resolution 3D‐printed polymer composites. The resulting materials strike an optimal balance between thermal conductivity, dielectric properties, and mechanical flexibility, making them perfect for applications that demand exceptional thermal control and mechanical performance, such as artificial intelligence (AI)‐driven systems and flexible wearable technologies.

Reliable, long‐term monitoring of health data is becoming increasingly essential in modern healthcare. While computational and machine learning capabilities continue to advance, the lack of lightweight, conformable, and customizable hardware remains a key limitation. In the context of heart health, traditional electrocardiogram (ECG) electrodes are rigid and often uncomfortable for continuous wear. Existing soft electrodes tend to be either cost‐prohibitive or unreliable over extended use. In this work, all‐polymer, 3D‐printed, highly stable, and conformable ECG patches are developed for long‐term signal acquisition. Through material optimization, composite materials with electrical conductivity up to 1.7 S cm ⁻¹ are developed, maintaining over 85% of their conductivity after 60 days of exposure to open air. These materials also exhibit remarkable stretchability (strain at break up to 253%) and high mechanical strength (tensile strength of 25 MPa). The formulated inks are fully compatible with 3D material extrusion techniques, significantly reducing manufacturing costs. The printed electrodes are flexible, stretchable, and capable of recording high‐quality ECG signals, performing comparably to state‐of‐the‐art metal electrodes, even after more than a month of use‐and‐store in open air.