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Abstract This study explores a novel multi-material 3D printing technique for fabricating bioinspired hydrogel-Rochelle salt composites, focusing on optimizing concentration, cooling, and coating parameters to enhance material performance. The hydrogel-Rochelle salt composite is a promising material due to its lightweight, mechanical robustness, and piezoelectric properties, making it suitable for applications in sensors, medical devices, and structural materials. A series of concentration tests was conducted to determine the optimal Rochelle salt concentration for achieving efficient curing depth and exposure time. The results identified 50wt% hydrogel/50wt% Rochelle salt as the optimal concentration, providing a balanced curing profile essential for ensuring reliable layer adhesion and structural consistency. To enable controlled crystallization, a cooling process was introduced, with a cooling time of 15 minutes found to be sufficient for complete crystallization to a depth of 500 microns. Thermal imaging and microscopy confirmed the stability of the crystalline structure within the hydrogel matrix, ensuring the material’s functional integrity. Additionally, applying a coating to the printed structure significantly improved surface uniformity and durability, embedding the crystalline elements more effectively within the hydrogel matrix and enhancing the composite’s overall structural integrity. This coating process allowed the composite to withstand repeated printing cycles, facilitating the construction of layered, multi-material structures with improved mechanical and functional properties. The results highlight the importance of fine-tuning concentration, cooling time, and coating techniques to achieve optimal performance in multi-material 3D printing. By addressing these factors, the study demonstrates a reliable approach to producing hydrogel-Rochelle salt composites with high structural quality and piezoelectric functionality. This method not only enhances the material’s durability and adhesion between layers but also opens new possibilities for creating customized, multifunctional materials. The developed process holds significant promise for applications that require precise control over material properties, such as wearable electronics, medical implants, and lightweight structural components. In conclusion, this research provides valuable insights into the fabrication of hydrogel-Rochelle salt composites through advanced 3D printing techniques. The findings offer a foundation for future exploration in multi-material printing and composite fabrication, paving the way for the development of versatile materials with tailored properties for diverse applications.
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This content will become publicly available on January 23, 2026
High-k, Low-Loss Ceramic-Thermoplastic Composite Feedstock Filaments for Fused Deposition Modeling of Microwave and mm-Wave Devices
Maturing of additive manufacturing (AM) techniques has increased their utilization for fabricating radio frequency (RF) and microwave devices. Solid composites used in material extrusion AM have experienced considerable expansion over the past decade, incorporating functional properties into 3D-printed objects. There are encouraging indications from AM material research that electrically efficient AM materials can be discovered. These materials would be useful for producing microwave components in the future. One of the enabling techniques for fabricating these materials is to incorporate nano/microparticles or fillers into thermoplastic material. Composite material 3D printing is a novel approach to managing materials’ microwave properties. While extrinsic qualities (effective permittivity) can be controlled by shape and porosity management, intrinsic attributes are tied to the composition of composites. Furthermore, combining various materials to increase the spectrum of available microwave characteristics is made possible by multi-material 3D printing. In this chapter, we explore different methodologies to fabricate ceramic/thermoplastic composites for fused deposition modeling (FDM) of RF and microwave devices. Analytical models for predicting effective permittivity of the composite are discussed and application examples of FDM printed RF, microwave and mm-wave devices employing composites are presented.
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- Award ID(s):
- 2329207
- PAR ID:
- 10635806
- Publisher / Repository:
- IntechOpen
- Date Published:
- Subject(s) / Keyword(s):
- ceramic-thermoplastic composite, fused deposition modeling, high-k, low-loss dielectrics, dielectric constant, dielectric loss tangent
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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