Fused filament fabrication (FFF), the printing of parts through the deposition of layers of melted thermoplastic, is one of the most widely used 3D printing processes due to its ease of use, low cost and accessibility. In this work, integration of 3D printed sensors and interconnect between embedded components into a printed part is demonstrated in an FFF process for the first time. The use of printed active materials for sensing allows interactivity with the end user through mechanisms like touch and temperature. Through dual extrusion in a low cost commercial printer, printing of both a conductive thermoplastic composite and a non-conducting filament are combined to create complex patterns. The piezoresistive and thermally responsive properties of the thermoplastic composite are used to create several different sensor modalities including a piezoresistive strain sensor, a contact switch and a resistive temperature sensor. A heated insertion technique is then developed for embedding of electrical components. The conductive thermoplastic is also used to incorporate a 3D printed circuit board in the same part, including in-line embedding within the body of the part during the printing process. The sensor performance and component embedding properties are characterized, and the process is used to print systems including relaxation oscillators and op-amp interface circuits for sensor monitoring.

熔融长丝制造（FFF）是通过沉积熔融的热塑性塑料层进行零件的印刷，由于其易用性，低成本和可访问性，是最广泛使用的3D打印过程之一。在这项工作中，首次在FFF过程中展示了3D打印传感器的集成以及嵌入式组件之间的互连到打印零件中。使用印刷的活性材料进行感测可以通过诸如触摸和温度之类的机制与最终用户互动。通过在低成本商用打印机中进行双重挤压，可以将导电热塑性复合材料和非导电丝的打印结合在一起以创建复杂的图案。热塑性复合材料的压阻和热响应特性用于创建几种不同的传感器形式，包括压阻应变传感器，接触开关和电阻温度传感器。然后，开发了一种热插入技术来嵌入电气组件。导电热塑性塑料还用于在同一零件中并入3D印刷电路板，包括在印刷过程中在线嵌入零件主体内。表征了传感器的性能和元件的嵌入特性，并将该过程用于打印系统，包括张弛振荡器和用于监控传感器的运算放大器接口电路。然后，开发了一种热插入技术来嵌入电气组件。导电热塑性塑料还用于在同一零件中并入3D印刷电路板，包括在印刷过程中在线嵌入零件主体内。表征了传感器的性能和元件的嵌入特性，并将该过程用于打印系统，包括张弛振荡器和用于监控传感器的运算放大器接口电路。然后，开发了一种热插入技术来嵌入电气组件。导电热塑性塑料还用于在同一零件中并入3D印刷电路板，包括在印刷过程中在线嵌入零件主体内。表征了传感器的性能和元件的嵌入特性，并将该过程用于打印系统，包括张弛振荡器和用于监控传感器的运算放大器接口电路。