Electromagnetic wave-induced localized heating of CNT filled polymer composites for enhanced inter-bead diffusive bonding of fused filament fabricated parts

A process for manufacturing a three-dimensional object on a support platform, the process comprising:

• (a) selecting a polymer filament having an outer layer, wherein the outer layer has an electrically conductive percolated network of an electrically conductive nanomaterial;
• (b) extruding the polymer filament through a nozzle;
• (c) moving the nozzle relative to the support platform to deposit a first layer of the polymer filament onto the support platform;
• (d) applying a second layer of the polymer filament adjacent the first layer to form a filament to filament interface to form the three-dimensional object on the support platform;
• (e) generating an electromagnetic wave;
• and
• (f) applying the electromagnetic wave to the first and second layers of polymer filament to produce a predetermined temperature profile in the polymer filament through the absorption of the electromagnetic wave by the electrically conductive percolated network of the electrically conductive nanomaterial sufficient to cause interfacial polymer diffusion of the filament to filament interface to form a weld in the three-dimensional object.