Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Freeman, Thomas B.; Foster, Kyle E. O.; Morgan, Karl B.; Melendez, Isabel; Odukomaiya, Adewale; Boetcher, Sandra K. S.

doi:10.1007/s40964-025-01277-0

Fused filament fabrication of thermoplastic polyurethane composites with microencapsulated phase-change material

Journal Article · Wed Aug 20 00:00:00 EDT 2025 · Progress in Additive Manufacturing

DOI:https://doi.org/10.1007/s40964-025-01277-0· OSTI ID:2587295

Freeman, Thomas B. ^[1]; Foster, Kyle E. O. ^[1]; Morgan, Karl B. ^[2]; Melendez, Isabel ^[2]; ^[1]; Boetcher, Sandra K. S. ^[3]

National Renewable Energy Laboratory (NREL), Golden, CO (United States)
Embry-Riddle Aeronautical University, Daytona Beach, FL (United States)
National Renewable Energy Laboratory (NREL), Golden, CO (United States); Embry-Riddle Aeronautical University, Daytona Beach, FL (United States)

Here, the present study examines the thermal energy storage (TES) effectiveness and printability of microencapsulated phase-change material (MEPCM) combined with thermoplastic polyurethane (TPU) for fused filament fabrication (FFF). Two formulations were assessed: 24D MEPCM, which changes phase at 24 ° C, compounded with TPU pellets and 43D MEPCM, which changes phase at 43 ° C, integrated with TPU powder. These combinations are designed to evaluate the effectiveness of the form of the TPU (pellets versus powder) in the FFF process. The investigation includes a comprehensive analysis of thermal characteristics, encompassing phase-change temperature, latent heat of fusion, thermal conductivity, and thermal decomposition, which are assessed through differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). Additionally, mechanical properties, including stress-strain behavior, are examined to evaluate material suitability for TES applications, while microstructural visualization is used to provide deeper insights into material performance, structural integrity, and the quality of printed components. The 24D MEPCM and TPU pellets formulation experienced a significant loss of approximately 39.6% of PCM during filament extrusion and printing, resulting in a reduced effective latent heat. Therefore, further characterization of the pellet formulation was discontinued due to excessive leakage. In contrast, the 43D MEPCM and TPU powder formulation demonstrated minimal PCM loss, with the 60 wt.% composition achieving an effective latent heat of 132 J/g. This value represents the highest effective latent heat currently documented in the literature for PCM-polymer-composite materials produced using an FFF-based additive manufacturing process.

View Accepted Manuscript (DOE)

Research Organization:: National Renewable Energy Laboratory (NREL), Golden, CO (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Materials & Manufacturing Technologies Office (AMMTO)

Grant/Contract Number:: AC36-08GO28308

OSTI ID:: 2587295

Report Number(s):: NREL/JA--5500-90383

Journal Information:: Progress in Additive Manufacturing, Journal Name: Progress in Additive Manufacturing Vol. 10; ISSN 2363-9512; ISSN 2363-9520

Publisher:: SpringerCopyright Statement

Country of Publication:: United States

Language:: English

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