Effective synthesis of electrically conductive polymer composites based on butyl methacrylate and graphene for 3D printing

This work is devoted to the development of electrically conductive polymer composite materials based on butyl methacrylate using the method of radical polymerization in Pickering emulsion in situ graphene oxide (GO), which was subsequently chemically reduced to a graphene-like electrically conductive form. As part of this study, a series of poly(butyl methacrylate) (PBMA) composites with reduced graphene oxide (rGO) were synthesized, with mass fractions of rGO ranging from 0.67% to 0.82%. The obtained composites exhibited a broad range of molecular weights, from 120 to 390 kDa. The electrophysical properties of the composites were investigated, revealing electrical conductivity values about 10⁻⁶–10⁻⁵ S/cm. The maximum value of electrical conductivity is 3.13 × 10⁻⁵ (± 0.1) S/cm. It is particularly noteworthy that GO itself was present in the polymerization system, eliminating the need for external low-molecular-weight surfactants. Additionally, uniform filler distribution within the matrix was achieved, as the polymer particles were coated with GO during the emulsion formation stage of polymerization. As demonstrated, the resulting composite materials can be processed by extrusion without loss of electrical conductivity and can also be used as material for Fused Deposition Modeling 3D printing. PBMA/rGO-based materials show promise for microwave electromagnetic shielding applications and open new possibilities for creating electrically conductive composites at the polymer synthesis stage. • After polymerization the composite has a segregated structure. • Synthesis conditions do not critically affect electrical conductivity. • PBMA/rGO is a screen of absorbing type of microwave radiation. • The resulting material is suitable for 3D printing of conductive parts.