(378g) Green Additive Manufacturing of Multilayered Carbon Composites

Carbon-carbon (C-C) composites are in high demand across aviation, automotive, and defense industries due to their exceptional thermal and thermo-mechanical properties, such as low density and a remarkably low coefficient of thermal expansion. These attributes often outperform traditional alloys and composites, making C-C materials ideal for high-performance components. However, widespread adoption is hindered by existing manufacturing challenges namely high cost, slow production rates, and labor-intensive processes. This study presents a sustainable alternative by converting the biodegradable polyvinyl alcohol (PVA) into high-performance carbon materials. Through sulfonation-induced crosslinking followed by pyrolysis, PVA is transformed into carbon with consistent yield and controlled dimensional stability. The resulting carbon exhibits excellent electrical, mechanical, and thermal properties, positioning it as a strong candidate for energy storage and thermoelectric generation applications. To further enhance its performance, multiwalled carbon nanotubes (MWCNTs) are incorporated into the carbon matrix using a novel extrusion-based 3D printing technique: multiphase direct ink writing (MDIW). This approach enables precise control over the composite’s internal architecture and nanoparticle distribution within a multilayered structure. Overall, this approach highlights the potential of a biodegradable precursor for producing high-quality carbons and provides a scalable pathway to advanced carbon materials for next-generation energy and thermal management applications.