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3D Printing a Mechanically-Tunable Acrylate Resin on a Commercial DLP-SLA Printer.

ABSTRACT: Multi-material 3D printing with several mechanically distinct materials at once has expanded the potential applications for additive manufacturing technology. Fewer material options exist, however, for additive systems that employ vat photopolymerization (such as stereolithography, SLA, and digital light projection, DLP, 3D printers), which are more commonly used for advanced engineering prototypes and manufacturing. Those material selections that do exist are limited in their capacity for fusion due to disparate chemical and physical properties, limiting the potential mechanical range for multi-material printed composites. Here, we present an ethylene glycol phenyl ether acrylate (EGPEA)-based formulation for a polymer resin yielding a range of elastic moduli between 0.6 MPa and 33 MPa simply by altering the ratio of monomer and crosslinker feedstocks in the formulation. This simple chemistry is also well suited to form seamless adhesions between mechanically dissimilar formulations, making it a promising candidate for multi-material DLP 3D printing. Preliminary tests with these polymer formulations indicate that variability due to molecular differences between hard and soft formulations is near net shape and less than 3% of the prescribed dimensions, comparable to existing commercial DLP and SLA resins, with unique advantages of a wide range of elastomer stiffness and seamless fusion for 3D printing of structurally detailed and mechanically heterogeneous composites.

SUBMITTER: Borrello J

PROVIDER: S-EPMC6516765 | biostudies-literature | 2018 Oct

REPOSITORIES: biostudies-literature

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Project description:Three-dimensional printing is regarded as a future-oriented additive manufacturing technology that is making significant contributions to the field of polymer processing. Among the 3D printing methods, the DLP (digital light processing) technique has attracted great interest because it requires a short printing time and enables high-quality printing through selective light curing of polymeric materials. In this study, we report a fabrication method for ABS-like resin composites containing polyaniline (PANI) nanofibers and graphene flakes suitable for DLP 3D printing. As-prepared ABS-like resin composite inks employing PANI nanofibers and graphene flakes as co-fillers were successfully printed, obtaining highly conductive and mechanically robust products with the desired shapes and different sizes through DLP 3D printing. The sheet resistance of the 3D-printed composites was reduced from 2.50 × 1015 ohm/sq (sheet resistance of pristine ABS-like resin) to 1.61 × 106 ohm/sq by adding 3.0 wt.% of PANI nanofibers and 1.5 wt.% of graphene flakes. Furthermore, the AP3.0G1.5 sample (the 3D-printed composite containing 3.0 wt.% of PANI nanofibers and 1.5 wt.% of graphene flakes) exhibited 2.63 times (22.23 MPa) higher tensile strength, 1.47 times (553.8 MPa) higher Young's modulus, and 5.07 times (25.83%) higher elongation at break values compared to the pristine ABS-like resin with a tensile strength of 8.46 MPa, a Young's modulus of 376.6 MPa, and an elongation at break of 5.09%. Our work suggests the potential use of highly conductive and mechanically robust ABS-like resin composites in the 3D printing industry. This article not only provides optimized DLP 3D printing conditions for the ABS-like resin, which has both the advantages of the ABS resin and the advantages of a thermoplastic elastomer (TPE), but also presents the effective manufacturing process of ABS-like resin composites with significantly improved conductivity and mechanical properties.

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3D Printing a Mechanically-Tunable Acrylate Resin on a Commercial DLP-SLA Printer.

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