Progress in selective laser sintering ofmultifunctional polymer composites for strain- and self-sensing applications

Recent decades have witnessed significant advancements in additive manufacturing (AM) of polymer composites, leading to the development of material systems with intricate architecture and composition. Selective laser sintering (SLS), among various AM methods, offers numerous advantages such as high mechanical strength in printed parts, recyclability of unused powders, and the ability to print large batches without support structures. Moreover, SLS has remarkably succeeded in fabricating electrically conductive polymer composites (ECPCs) with exceptional functional performance which is attributed primarily to the formation of a segregated filler network along the powder particle boundaries. This review aims to delve into SLS for processing polymer-based materials, examining consolidation mechanisms and process parameters, specifically highlighting advancements in electrically conductive polymer composites with a focus on piezoresistive strain-sensing materials and self-sensing structures. Furthermore, the review seeks to elucidate the complex process-structure-property relationships in SLS 3D printed polymer composites, providing an exhaustive overview of the current state-of-the-art in piezoresistive polymer composites.