With an exponential rise in the popularity and availability of additive manufacturing (AM), a large focus has been directed toward research in this topic's movement, while trying to distinguish themselves from similar works by simply adding nanomaterials to their process. Though nanomaterials can add impressive properties to nanocomposites (NCs), there are expansive amounts of opportunities that are left unexplored by simply combining AM with NCs without discovering synergistic effects and novel emerging material properties that are not possible by each of these alone. Cooperative, evolving properties of NCs in AM can be investigated at the processing, morphological, and architectural levels. Each of these categories are studied as a function of the amplifying relationship between nanomaterials and AM, with each showing the systematically selected material and method to advance the material performance, explore emergent properties, as well as improve the AM process itself. Innovative, advanced materials are key to faster development cycles in disruptive technologies for bioengineering, defense, and transportation sectors. This is only possible by focusing on synergism and amplification within additive manufacturing of nanocomposites.

Additive Manufacturing In article number 2103334, Hilmar Koerner and co‐workers discuss how, with the growth in additive manufacturing, such as 3D printing, nanocomposites have experienced a resurgence due to novel emergent material properties, which are enabled by digitally dialing in morphology over several length scales. Topology optimization of 3D printed nanocomposites takes this to another level with unprecedented control over morphology and material response in structural and electro‐optical applications.

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As fused filament fabrication (FFF) continues to gain popularity, many studies are turning to nanomaterials or optimization of printing parameters to improve the materials’ properties; however, many overlook how materials formulation and additive manufacturing (AM) processes cooperatively engineer the evolution of properties across length scales. Evaluating the in-process evolution of the nanocomposite using AM will provide a fundamental understanding of the material’s microstructure, which can be tailored to create unique characteristics in functionality and performance. In this study, the crystallinity behavior of polyetheretherketone (PEEK) was studied in the presence of carbon nanotubes (CNTs) as a nucleation aid for improved crystallization during FFF processing. Using various characterization techniques and molecular dynamics simulations, it was discovered that the crystallization behavior of extruded filaments is very different from that of 3D printed roads. Additionally, the printed material exhibited cold crystallization, and the CNT addition increased the crystallization of printed roads, which were amorphous without CNT addition. Tensile strength and modulus were increased by as much as 42 and 51%, respectively, due to higher crystallinity during printing. Detailed knowledge on the morphology of PEEK–CNT used in FFF allows gaining a fundamental understanding of the morphological evolution occurring during the AM process that in turn enables formulating materials for the AM process to achieve tailored mechanical and functional properties, such as crystallinity or conductivity.

Though a revolutionary process, additive manufacturing (AM) has left more to be desired from printed parts, specifically, improved interlayer strength and minimal defects such as porosity. To overcome these common issues, nanocomposites have become one of the most popular materials used in AM, with various nanoparticles used to achieve a variety of characteristics. The use of these technologies together allows for both to synergistically enhance the final printed parts by improving the process and products simultaneously. Here, we introduce a novel, scalable technique to coat ABS pellets with cellulose nanocrystal (CNC) bonded carbon nanotubes (CNT), to improve the adhesion between layers as well as the mechanical properties of printed parts. An aqueous suspension of CNT-CNC is used to coat ABS pellets before they are dried and extruded into filament for printing. The filament produced using this manufacturing method showed an increase in tensile and interlayer strength as well as improved thermal conductivity. This process uses water as solvent and pristine nanoparticles without the need for any functionalization or surfactants, promoting its scalability. This process has the potential to be used with various polymers and nanoparticles, which allows the materials to be specifically tailored to the end application, (i.e. strength, conductivity, antibacterial, etc.). These nanocomposite filaments have the potential to revolutionize the way that additive manufacturing is utilized in a variety of industries.