3D-printed gradient conductivity and porosity structure for enhanced absorption-dominant electromagnetic interference shielding

The application of 3D printing for the development of electromagnetic interference (EMI) shielding materials is currently constrained by a limited range of material options and design schemes. In this work, we developed conductivity-modulated polylactic acid (PLA)-MXene composite filaments for fused deposition modeling (FDM) 3D printing, demonstrating excellent printability and durability. Utilizing these filaments, we propose a design scheme focused on absorption-dominant EMI shielding materials. Our design features non-conductive PLA with larger pores at the incident surface, transitioning to layers with increasing conductivity and decreasing pore sizes. This gradient structure minimizes reflection by providing impedance matching and enhances absorption by extending the propagation path of EM waves through multiple reflections and scattering within the pores. Additionally, interfacial polarization effects between air, PLA, and MXene nanoflakes strengthen the absorption mechanisms. Both simulation and experimental results confirm that the combined gradient conductivity and pore size structures significantly improve EMI shielding effectiveness (EMI SE) and absorptivity, achieving an EMI SE of 65 dB and an absorptivity of 0.76 in the X-band. Our findings underscore its potential to create adaptable, high-performance EMI shields suitable for complex geometries and reducing secondary interference.