Viscosity of Mono‐ and Polydisperse Mixtures of Photopolymer and Rigid Spheres for Manufacturing of Engineered Composite Materials Using Vat Photopolymerization

Abstract

Vat photopolymerization (VP) additive manufacturing involves selectively curing low‐viscosity photopolymers via exposure to ultraviolet light in a layer‐wise fashion. Dispersing filler materials in the photopolymer enables tailored end‐use properties, but also increases the viscosity and the timescale associated with interparticle network structural recovery postshear. These rheological properties influence self‐leveling and recoating of the liquid photopolymer mixture during VP. Herein, viscosity of photopolymer and rigid spherical glass microparticles (filler) is experimentally determined as a function of filler fraction, filler size distribution (mono‐ and polydisperse), shear rate, and temperature, which are important VP process parameters. Employing existing viscosity models for mono‐ and polydisperse polymer mixtures demonstrates that particle–particle interactions and the formation of nonspherical clusters of particles strongly affect the viscosity of both monodisperse and polydisperse mixtures with particle volume fractions > 0.05 due to agglomeration/deagglomeration of clusters at elevated shear rates. Consequently, unmodified viscosity models, which assume uniformly dispersed, rigid, spherical particles, are applicable only for mixtures with particle volume fractions < 0.05. It is shown that modifying model parameters such as the fluidity limit and intrinsic viscosity, which explicitly account for nonspherical clusters of particles, improves agreement between viscosity models and experiments, in particular when using a fractal approach.