We develop highly concentrated vinyltriethoxysilane-coated zirconium oxide/acrylate composites with various nano-to micro-particle ratios as three-dimensional printing materials for use in a supportless stereolithography process. The incorporation of nano-particles with micro-particles at certain particle volume ratios resulted in densely packed network structures that generate good particle dispersion as well as a uniform particle distribution. Structural deformation and time-dependent structural recovery were analyzed by the three interval thixotropy test. We found sustained solid-like behaviors in the composites composed of 50:50 and 30:70 nano-particle to micro-particle ratios. Phase diagrams using structural deformation parameters confirm that the 50:50 and 30:70 composite's structure contributes to their good colloidal stability and printability. The addition of nano-particles also enhances the total heat release during the curing process due to improved light scattering, and the amount of heat release affects the degree of photo-polymerization in the printing material.
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