3D-printed honeycomb structure filled with nanofillers for efficient electromagnetic interference shielding performance

The novelty of this research aims to fabricate effective electromagnetic interference (EMI) shielding materials to prevent electrical components from EMI. In this work, Solidworks was used to design a honeycomb structure with different distances between parallel edges of the structure. All honeycomb structures were manufactured using Creality Ender-3, a 3D printer. The holes of the structure were filled with plasticine/carbon black/aluminum powder. SEM and FTIR tests were used to showcase the presence of nanofillers in the plasticine. The Central Composite design, a response surface methodology method, has been used to design and analyze the EMI shielding effectiveness (EMI SE) experiments. Mathematical models have been developed using the EMI SE results to predict the outcomes and verify them with error estimation. By incorporating the carbon black/aluminum/plasticine composite into the 3D-printed honeycomb structures, the honeycomb structure with a thickness of 6 mm shows a considerably high total EMI SE of 23.8 dB in the 8–12 GHz frequency range. According to the results of an optimization study, 1.5 wt.% of carbon black, 0.5 wt.% of aluminum powder, and a 4-mm distance between parallel edges are the optimal parameters for achieving the highest total EMI SE. Overall, the results show a 3D-printed honeycomb structure filled with nanofillers is a fantastic material employed in various fields, including defense and aviation, where lighter weight and EMI SE properties are critical.