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The purpose of this study is to demonstrate the usage of three-dimensionally (3D) printed polylactic acid (PLA)-carbon black (CB) conductive polymer composite in the measurement of the void fraction and liquid level.

PLA-CB conductive polymer composite is 3D printed through fused deposition modelling (FDM) technique and used as a capacitive sensor for void fraction measurement and liquid level sensing. The sensitivity of 3D printed ring and concave type capacitive sensors are compared for void fraction measurement. The effect of electrode length, thickness and pipe dimension on the capacitance achievable for the particular void fraction is studied. Concept of fringing capacitance is used for the sensing of liquid level.

Compared to the concave design comprising four electrodes, the ring-type capacitive sensor produced better results in void fraction measurement. Increase in pipe diameter and electrode length results in the enhancement of capacitance arising from specific void fraction. For a 100 mm diameter pipe, the capacitance of the 150 mm-long concave electrode (0.4 mm thick) increased from 9.98 to 67.77 pF as the void fraction decreased from 100% to 0%. Development of the fringing capacitance in 3D printed PLA-CB composite helps in the measurement of liquid level. Both parallel finger topology and interdigital electrode configuration are able to sense the liquid level.

Ability of the 3D printed conductive PLA-CB composite to act as a capacitive sensor is experimentally analysed. Performance of different electrode configuration is tested for both void fraction measurement and liquid level sensing. Results of experimentation prove that FDM printed PLA-CB composite is suitable for the void fraction and liquid level measurement.