A Combined Experimental, Theoretical and Simulation Approach on the Effects of GNPs and MWCNTs on Joule Heating Behavior of 3D Printed PVDF Nanocomposites

The thermal behavior of 3D-printed polyvinylidene fluoride (PVDF)-based composites enhanced with carbon nanotubes (CNTs), graphene nanoplatelets (GNPs), and their hybrid formulations was investigated under Joule heating at applied voltages of 2, 3, and 4 V. The influence of filler type and weight fraction on both electrical and thermal conductivity was systematically assessed using a Design of Experiments (DoE) approach. Response Surface Methodology (RSM) was employed to derive an analytical relationship linking conductivity values to filler loading, revealing clear trends and interaction effects. Among all tested formulations, the composite containing 6 wt% GNP exhibited the highest performance in terms of thermal response and electrical conductivity, reaching a steady-state temperature of 88.1 °C under an applied voltage of just 4 V. This optimal formulation was further analyzed through multiphysics simulations, validated against experimental data and theoretical predictions, to evaluate its effectiveness for potential practical applications—particularly in de-icing systems leveraging Joule heating. The integrated experimental–theoretical–numerical workflow proposed herein offers a robust strategy for guiding the development and optimization of next-generation polymer nanocomposites for thermal management technologies.