Comparative Analysis of Solid and Foamed PA6 Composite Architectures Reinforced With Graphene Nanoplatelets

Lightweight polymer composites combining solid and foamed structures offer significant potential for balancing mechanical performance and weight reduction. In this study, poliamide 6/graphene nanoplatelet (PA6/GnP) architectures were systematically investigated to establish processing–structure–property relationships. Solid composites containing 1–3 wt.% GnP showed that 3 wt.% GnP provided the highest tensile strength and modulus, accompanied by reduced elongation. The introduction of 3–9 wt.% chemical blowing agent (CBA) generated foamed structures with increased porosity, leading to reduced stiffness and strength, particularly at higher CBA contents due to structural heterogeneity. GnP incorporation improved flame‐related performance by suppressing dripping and reducing smoke emission, while excessive CBA negatively affected fire behavior. Thermal analysis revealed that GnP slightly enhanced thermal stability, whereas foaming reduced thermal resistance and increased moisture sensitivity. Overall, this study demonstrates that the combined use of GnP and controlled chemical foaming enables the tailoring of mechanical, thermal, and flame‐related properties in PA6‐based composites, providing a design strategy for lightweight load‐bearing polymer structures.