Additive Manufacturing Engineering for Electrochemistry: Conductive High‐Density Polyethylene Filament Expands the Materials Landscape

The integration of additive manufacturing within electrochemical engineering requires the development of novel functional materials capable of surviving harsh chemical environments while maintaining adequate electrical conductivity. This research direction explores the implementation and characterization of conductive high-density polyethylene (HDPE) filaments for fused filament fabrication (FFF). Traditional conductive filaments often rely on polylactic acid (PLA) or acrylonitrile butadiene styrene (ABS) matrices, which exhibit limited chemical resistance in highly acidic or alkaline electrochemical setups. By utilizing a conductive HDPE composite, this methodology aims to expand the materials landscape for chemically resilient, 3D-printed electrochemical components. The proposed framework provides structuring and guidance for evaluating the printability, surface roughness, electrical conductivity, and chemical stability

of the printed structures. Through systematic experimental testing and finite element analysis of the thermal and mechanical deposition process, the research establishes optimal printing parameters to minimize anisotropy and maximize conductive network percolation. Ultimately, this study supports the design and fabrication of robust, custom-geometry electrodes and reactor components, offering a comprehensive evaluation methodology for next-generation electrochemical additive manufacturing.

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