Polymeric conductive nanocomposite materials for integrated metal-free cabling and sensing

doctoral thesis examines polymeric conductive nanocomposites for metal-free electrical cabling and sensing. By adding carbon-based fillers like graphene nanoplatelets, graphene oxide, reduced graphene oxide, and carbon black to thermoplastic polymers, this research aims to create lightweight, sustainable, and multifunctional materials. Moreover, an intensive study concerning a bio-based filler, such as lignin, used as a graphene precursor and dispersed within a biodegradable matrix, such as poly(butylene adipate-co-terephthalate), was conducted. This thesis explores laser-induced graphene and laser-induced conductive tracks in graphene-filled composites to locally adjust the electrical properties of composite materials. In particular, the use of a CO2 laser to obtain conductive carbon patterns directly on polymeric composites is demonstrated in order to develop circuits and sensors without the use of metals or inks. The effects of laser parameters on morphology, graphitization, and conductivity were analyzed with Raman, SEM, FTIR, and electrical measurements. The thesis is also extensively focused on the development of devices and sensors aimed at demonstrating the practical feasibility of the laser activation process within an industrial framework. In this context, my research also encompassed other multifunctional materials, specifically in the field of conductive textiles for automotive applications. The common thread linking all the projects illustrated herein is the pursuit of environmental sustainability. This objective is underpinned by research into novel multifunctional and metal-free materials designed to reduce CO2 emissions through vehicle lightweighting, while ensuring they are either easily recyclable or biodegradable. The Graphene Flagship G+BOARD project, alongside industry partners (CRF, Technova, Apollo, Avanzare), helped scale these materials from lab prototypes to working demonstrators. The thesis includes two patent applications on laser-scribed conductive paths and polymer pressure sensors, and four peer-reviewed articles. This research offers a scalable approach to recyclable, carbon-based conductors that replace metals and support green and circular material design trends