3D‐Printed Functional Polymers and Nanocomposites: Defects Characterization and Product Quality Improvement

There have been continuing efforts toward improving printability and minimizing defects in 3D‐printed functional polymers and polymer nanocomposites (PNCs). While printability is essentially material related, and formation of defects is largely influenced by operational parameters, there is an interconnection between the factors influencing both. It is important to have a comprehensive insight on how these aspects interrelate to increase the prospect of improving part performance and widening the current range of applications of 3D‐printed polymer‐based functional materials. Therefore, this work first reviews various polymer 3D printing techniques and recent advances in 3D‐printed functional polymers and PNCs before discussing characterization and control of common defects in printed parts. Techniques for improving printability of polymer‐based functional materials are then discussed. Some opportunities for further developments in this area are highlighted in respect of polymer blending, immiscible blend nanocomposites, and a specific product development prospect. The major barrier to advances in 3D printing of functional polymeric materials is the development of novel printable materials that can meet the increasing demands in functional applications. Adequate knowledge about defects characterization, factors affecting their creation, and quantification of their effects is important for controlling and tailoring the properties of 3D‐printed functional materials.