Hi all:
We are working with adding carbon nanotubes to ABS and to a TPE with good results, although our loadings are modest. In the past, I extruded ceramic polymer blends through a 1" 24:1 killion extruder. I extruded a piezoelectric material (PZT), the YBaCuO superconductor, and a ferrite ceramic, often in a LDPE at loadings up to 50wt%. The wear was not as bad as you'd expect. The trick for all of them was to add a very low molecular weight lubricant to the blend. I used a couple types of oils to drop the extrusion pressure and lubricate the particles as they flow thru the die.
Another obvious note is to ensure that your particles are small enough for your die. In practice, that means the particles must be smaller than 1/12 of the die diameter. My only worry with the filastruder is the lack of a die pressure gauge. Its nice to know if your pressure is climbing out of the realm of safety.
Once we finish with the CNT loaded ABS, we will be looking at metal filled filament.
thanks,
David C.