Dataset for "Influence of Layer Height and Nozzle Diameter on the Resistivity of Additively Manufactured Electrically Conductive Structures Made by Material Extrusion"

Additive manufacturing (AM) via material extrusion (MEX) enables the production of electrically functional structures, such as sensors, actuators, and conductive interconnections. Electrical properties in these structures are influenced by nozzle diameter and layer height, requiring optimization to balance resolution, production time, and cost efficiency. This study investigates the effects of these parameters on electrical resistivity and surface roughness. Single-layer rectangular specimens were fabricated using an electrically conductive composite, with nozzle diameters varied in six increments and layer heights adjusted in 50µm steps within limits based on nozzle diameter. Statistical analysis confirmed that both parameters significantly impact resistivity and surface roughness. Minimal resistivity was observed at a layer height-to-nozzle diameter ratio of 40–60%. Ratios outside this range increased resistivity: lower ratios likely disrupted conductive networks due to higher shear rates, while higher ratios reduced melt pressure, impairing inter-strand contact. Additionally, increased surface roughness degraded electrical performance by reducing the conductive cross-section and strand contact area. These findings emphasize the critical role of process parameter optimization in MEX to improve the electrical properties of AM components, providing valuable insights into material-process interactions for Design for Additive Manufacturing.