3D-printed broadband electromagnetic wave-absorbing basalt/CF/PLA composites with a high current path for lightning strike protection

In this study, we used the three-dimensional (3D) printing method to design and fabricate a radar-absorbing structure (RAS) to protect against damage caused by lightning strikes. A carbon black-dispersed 3D filament was used as reinforcement in the composite, and metalized fibers served as the feedstock for 3D-printing. The return losses measured in the X-band and Ku-band (8.2–18 GHz) indicated a maximum return loss of −28.98 dB at 10.68 GHz, with a broad bandwidth of 6.56 GHz in the frequency range of 8.2-18 GHz. A coupled electrical–thermal analysis confirmed that the proposed carbon black-dispersed filament provided conductive paths, which contributed to direct current, energy dissipation, and lightning strike protection. The 3D-printing method ensured a sufficient level of electrical conductivity, limiting the area and depth of damage caused by lightning strikes. Therefore, 3D-printed-RASs, reinforced by electrically conductive materials, can effectively protect against lightning strikes.