Photopolymerization 3D Printing Research Articles

3D printing of cordierite glass-ceramics

Compared to traditional ceramic materials, glass-ceramics can also exhibit superior properties and are now widely used in cutting-edge national defense industries technology, aerospace, electronics, construction, and other fields. In this study, it is for the first time reported that novel photopolymerization 3D printable slurries using cordierite glass ceramic powder were prepared. The effects of slurry properties and printing process parameters on the warpage of the printed samples were studied. Cordierite glass-ceramic parts fabricated using photopolymerization 3D printing and heat treatment processes were studied to evaluate the effects of sintering parameters on the properties of the samples. The obtained additively manufactured cordierite glass-ceramics exhibit excellent microstructural and mechanical properties, with a maximum bending strength of 181 MPa, an increase of 95.66 % compared to that of the previously reported 3D printed cordierite ceramics. The underlying mechanisms of the glass and ceramic phase characteristics influence the density and the mechanical properties during and after the courses of sintering were also investigated and unveiled in detail. This study provides a viable method for manufacturing complex-shaped cordierite glass-ceramic components using 3D printing.

Sunflower pith inspired dual-gradient cellular polyurethane architecture with amplified mechanical functions

Artificial cellular materials with various mechanical functions are attracting increasing attentions from aerospace, transportation, and industrialization. However, many artificial cellular materials, despite of the hierarchically ordered structures and even unique performance to some, still lag behind many natural ones in amplification of mechanical functions owing to the limitations in intrinsic mechanical performance and sophisticated structural design. Herein, inspired with lightweight and high strength of sunflower piths, we proposed a dual-gradient structure consisting of pore size gradient and wall thickness gradient to engineer cellular architectures with desirable mechanical performance by harnessing vat photopolymerization 3D printing of double crosslinking networks polyurethane elastomer. The double-gradient cellular polyurethane architecture displays more exceptional capability in load-bearing and energy absorption compared with non– and single gradient structures. Besides, the specific compressive strength and energy absorption of the dual-gradient cellular architectures are 4 times higher than those of traditional mechanical metamaterial structures such as octet-truss lattice, gyroid lattice, and porous structure prepared with the same material. Potential mechanisms such as dual-gradient cellular structures to obtain selective flexural deformation behaviour increasing their energy absorption and dissipation capacity are fully elucidated. As the potential paradigms, we demonstrated the mechanical functions of biomimetic mechanical cellular architectures for efficient impact protection and noise isolation, which offered a promising perspective toward developing soft metamaterials with excellent mechanical functions for potential soft machines and engineering applications.

Vat Photopolymerization 3D Printing of Hydrogels Embedding Metal-Organic Frameworks for Photodynamic Antimicrobial Therapy.

Given the variability in wounds based on the underlying causes, personalized medicine and tailored care for patients with wounds are required to ensure optimal therapeutic outcomes. With the emergence of high-precision and high-efficiency photocuring 3D printing technology, there is the potential for its use in customizing precise shapes that can match complex wound sites, thereby providing better treatment for patients with wound infections. In this work, porphyrinic metal-organic framework (MOF) crystals, serving as the functional filler, were incorporated into gelatin methacrylate (GelMA) as a photocurable composite resin to investigate the capabilities of producing customizable wound dressings through vat photopolymerization 3D printing. The embedded MOF crystals allow for better control of the photopolymerization process due to photon competition with the photoinitiator, enabling the precise printing of complex structures. In addition, these crystals impart photothermal and photodynamic capabilities to the printed object. The antibacterial assay confirms the potent photothermal and photodynamic bactericidal properties of the printed GelMA/MOF hydrogels. The hydrogel with the highest MOF content exhibited over 99.99% antibacterial efficiency against both Gram-positive Staphylococcus aureus and Gram-negative Escherichia coli after 30 min of light exposure (∼30 mW/cm2, λ ≥ 420 nm). Simultaneously, hemolysis and cytotoxicity evaluations validated their excellent biocompatibility. The findings presented here introduce a strategy for integrating photosensitive MOF and 3D printing to fabricate size-adjustable photothermal/photodynamic monoliths and patches, opening perspectives toward personalized treatment for wound management.

Programmable Hydrogel-Based Soft Robotics via Encoded Building Block Design

Hydrogels have revolutionized the field of soft robotics with their ability to provide dynamic and programmable responses to different stimuli, enabling the fabrication of highly adaptable and flexible robots. This continual development holds significant promise for applications in biomedical devices, active implants, and sensors due to the biocompatibility of hydrogels. Actuation in hydrogel-based soft robotics relies on variations in material properties, structural design, or a combination of both to generate desired movements and behaviors. While such traditional approaches enable hydrogel actuation, they often rely on complex material design, bringing challenges to hydrogel fabrication and hindering practical use. Therefore, this work seeks to present a simplified and versatile approach for fabricating programmable single-component hydrogel-based soft robotics using an encoded building block design concept and 3D printing. A series of structural building blocks have been designed to achieve various actuation characteristics, including the direction, degree, and kinetics of actuation. By assembling these building blocks into various configurations, a broader range of actuation responses can be encoded, allowing for the fabrication of versatile, programmable soft robotics using a single uniform material through vat photopolymerization 3D printing. This approach enables adaptation to a wide range of applications, providing highly customizable encoding designs.

Itaconic Acid-Based Hydrogels with Flame Retardancy and High-Temperature Resistance via Vat Photopolymerization 3D Printing

Itaconic Acid-Based Hydrogels with Flame Retardancy and High-Temperature Resistance via Vat Photopolymerization 3D Printing

Unraveling the reinforcing mechanisms for cementitious composites with 3D printed multidirectional auxetic lattices using X-ray computed tomography

This study investigates the mechanical properties of cementitious composites with 3D-printed auxetic lattices, featuring negative Poisson’s ratios (auxetic behavior) in multiple directions. These lattices were fabricated using vat photopolymerization 3D printing, and three base materials with varying stiffness and deformation capacities were analyzed to determine their impact on the composites’ mechanical behavior. To unravel the reinforcing mechanisms of multidirectional auxetic lattices, which exhibit auxetic behavior in both planar and out-of-plane directions, X-ray computed tomography (X-ray CT) was utilized to analyze composite damage evolutions under different strain levels. The micro-CT characterization reveals that auxetic lattices more effectively constrain crack growth and dissipate energy by distributing stress evenly within the cement matrix. In contrast, due to lack of lateral confinement, the non-auxetic lattice reinforced composites primarily dissipate energy through extensive crack propagation and interfacial damage, leading to lower peak strength. When strain exceeding 5%, although the confinement from the auxetic behavior diminished with crack propagation, the lattice can still maintain the composite’s structural integrity, resulting in 1.7 times higher densification energy than conventional cement-based materials. These findings provide valuable insights for designing auxetic lattice-reinforced cementitious composites with enhanced load-bearing capacity and improved dissipation capabilities.

Digital Light Processing 3D‐Printed Porous Yttria‐Stabilized Zirconia with High‐Thermal Shock Resistance

Advances in vat photopolymerization 3D printing have the potential to significantly improve the production of ceramic materials for electrochemical energy devices. Solid oxide fuel cells (SOFCs) and solid oxide electrolysis cells (SOECs) necessitate high‐resolution ceramic manufacturing methods, as well as precisely controlled porosity (≈20–40%) for optimal gas transport. Achieving a balance between this porosity and mechanical integrity, especially under thermal stress, remains a challenge. Herein, the successful fabrication of porous yttria‐stabilized zirconia (YSZ) ceramics using vat photopolymerization 3D printing is demonstrated, achieving porosities ranging from 6% to 40% and corresponding grain sizes of ≈80–550 nm. It is found that 3D‐printed YSZ with ≈33% porosity exhibited a Weibull modulus of m = 5.3 and a characteristic strength of over 36 MPa. In the investigation, it is further revealed that these ceramics can withstand thermal shock up to 500 °C, retaining over 70% of their flexural strength. This remarkable performance suggests significant potential for 3D‐printed porous YSZ in SOFCs and SOECs, paving the way for potential improved efficiency, reduced fabrication costs, and innovative designs in these next‐generation clean energy technologies.

3D printed SiOC architecture towards terahertz electromagnetic interference shielding and absorption

Electromagnetic interference (EMI) shielding and absorption materials can effectively mitigate the undesired pollution or noise caused by terahertz (THz) waves. The development of THz EMI shielding materials that are primarily based on absorption mechanisms to avoid secondary pollution caused by reflection is still in big demand. Herein, an absorption-dominated precursor-derived SiOC ceramic (PDC-SiOC) architecture for THz wave EMI shielding and absorption was reported. The EMI shielding properties of the bulk SiOC ceramic were studied. More than 93 % of THz EM waves were absorbed by the synthesized SiOC ceramic from 1.2 to 1.6 THz. Furthermore, lightweight honeycomb-structured SiOC architecture which was inspired by the wings of moth was fabricated by vat photopolymerization 3D printing combined with following pyrolysis. The EMI shielding properties and mechanism of the honeycomb SiOC architecture in THz bands were also discussed. The highest shielding effectiveness (SE) of the honeycomb SiOC architecture was up to 64.1 dB, and the transmissivity was below 1.4 % from 0.2 to 1.6 THz. In addition, more than 97–99.8 % of THz waves were absorbed in 0.8–1.6 THz. The excellent EMI shielding performance of the architecture was mainly attributed to its outstanding THz EM wave absorption ability. Finally, the mechanical properties and thermal stability of the architecture were further studied. The compressive and flexural strength of honeycomb architecture was 1.2 and 16.5 MPa, respectively. The result also proved that the honeycomb SiOC architecture was resistant to high temperatures up to 1100 °C under inert atmosphere. This work provides promising high-efficiency architecture towards THz EMI shielding and absorption.

Study on performance regulation of electro-mechanical properties 3D printed BaTiO3/HA porous structure composite ceramic

BaTiO3/Ca10(PO4)6(OH)2 composite ceramic is an outstanding representative of piezoelectric biomaterials, with excellent biocompatibility and piezoelectric effect, and has potential applications in the field of bone tissue repair. In this work, vat photopolymerization 3D printing technology was used to fabricate triply periodic minimal surface structure BaTiO3/Ca10(PO4)6(OH)2 composite ceramic bone tissue scaffolds with different pore sizes and porosity, and their mechanical and electrical properties were studied. First, the ceramic slurry configuration process was optimized to obtain a ceramic slurry with high solid content (45 vol%) and excellent rheological properties. Then the effect of sintering temperature on microstructure, relative density, mechanical properties, and electrical properties is discussed. The results show that when sintering at 1300 °C, the BaTiO3/Ca10(PO4)6(OH)2 composite ceramic has the highest relative density (99.18 %), the highest compressive strength (44 MPa), large relative dielectric constant (379–389), and low dielectric loss. The polarization electric field strength of the BaTiO3/Ca10(PO4)6(OH)2 composite ceramic was set to 15 kV/cm through the test of the hysteresis loop. Finally, based on multi-physics coupled finite element simulation, the effects of different porosity and different pore sizes on stress distribution and piezoelectric potential were analyzed, and the relationship between them was explored through experiments. The results show that as the porosity increases and the pore size decreases, the mechanical properties of the scaffold decrease significantly, and its compressive strength ranges between 1.67 and 4.26 MPa; as the porosity increases and the pore size increases, the piezoelectric coefficient (d33) of the scaffold showed a decreasing trend, and its d33 ranged between 2 and 9 pC/N. The mechanical and electrical properties of the scaffold meet the performance requirements of cancellous bone. In summary, this work provides a strategy for the application of customized BaTiO3/Ca10(PO4)6(OH)2 composite ceramic scaffolds in new-generation orthopedic implants.

Vat photopolymerization 3D printing of glass microballoon-reinforced TPMS meta-structures

Advancements in additive manufacturing coincide with the influx of assiduous research in realizing complex structures using printable composite materials with tunable properties. In this research study, photocurable resins with a broad range of mechanical properties were hybridized with ceramic particles to engineer the overall mechanical response. The newly formulated printable resins comprised up to 20 wt.% glass microballoons, balancing the tunability of the composite properties and manufacturability by overcoming light-reinforcement challenges. The compressive and tensile bulk properties were first assessed using additively manufactured samples tested under quasi-static loading. Complementary digital image correlation (DIC) was used to resolve the strain fields, revealing insights about the mechanical behavior and failure modes as a function of reinforcement weight ratio. Despite the expected hyperelastic constitutive behavior and shared macromolecular composition, the neat and hybridized photocurable resins exhibited distinctive mechanical behavior, leading to the characterization of the dynamic properties as a function of temperature to ascertain the underpinnings of respective responses. Triply periodic minimal surface (TPMS) structures were also manufactured using the vat photopolymerization approach to demonstrate the utility of newly formulated printable composite resins. The printed structures were tested under compression at a quasi-static loading rate. The DIC-resolved strains revealed the underlying structural mechanics as a function of the material properties. This case study correlates the mechanics governing particulate-reinforced elastomers with the observed variations in strain development, stiffness, load-bearing capacity, and specific energy absorption for TPMS structures. Finite element analysis (FEA) based on hyperelastic potential and using the properties of the bulk resin closely matched the deformation patterns from the experimental DIC results. The outcomes of this research reveal the potential for tunable, 3D printed sports gear for impact mitigation in various biomechanical loading conditions.

A virtual visualization method for improving the manufacturing accuracy based VPP 3D printers

Compared to traditional vat photopolymerization 3D printing methods, pixel blending technique provides greater freedom in terms of user-defined lighting sources. Based on this technology, scientists have conducted research on 3D printing manufacturing for elastic materials, biologically inert materials, and materials with high transparency, making significant contributions to the fields of portable healthcare and specialty material processing. However, there has been a lack of a universal and simple algorithm to facilitate low-cost printing experiments for researchers not in the 3D printing industry. Here, we propose a mathematical approach based on morphology to simulate the light dose distribution and virtual visualization of parts produced using grayscale mask vat photopolymerization 3D printing technology. Based on this simulation, we develop an auto-correction method inspired by circle packing to modify the grayscale values of projection images, thereby improving the dimensional accuracy of printed devices. This method can significantly improve printing accuracy with just a single parameter adjustment. We conducted experimental validation of this method on a vat photopolymerization printer using common commercial resins, demonstrating its feasibility for printing high precision structures. The parameters utilized in this method are comparatively simpler to acquire compared to conventional techniques for obtaining optical parameters. For researchers in non-vat photopolymerization 3D printing industry, it is relatively user-friendly.

Polymer Matrix Nanocomposites Fabricated with Copper Nanoparticles and Photopolymer Resin via Vat Photopolymerization Additive Manufacturing.

This investigation explores the fabrication of polymer matrix nanocomposites via additive manufacturing (AM), using a UV photopolymerization resin and copper nanoparticles (Cu-NPs) with vat photopolymerization 3D printing technology. The aim in this study is to investigate the mentioned materials in different formulations in terms of inexpensive processing, the property related variability, and targeting multifunctional applications. After the AM process, samples were post-cured with UV light in order to obtain better mechanical properties. The particles and resin were mixed using an ultrasonicator, and the particle contents used were 0.0, 0.5, and 1.0 wt %. The process used in this investigation was simple and inexpensive, as the technologies used are quite accessible, from the 3D printer to the UV curing device. These formulations were characterized with scanning electron microscopy (SEM) to observe the materials' microstructure and tensile tests to quantify stress-strain derived properties. Results showed that, besides the simplicity of the process, the mixing was effective, which was observed in the scanning electron microscope. Additionally, the tensile strength was increased with the UV irradiation exposure, while the strain properties did not change significantly.

From Grayscale Photopolymerization 3D Printing to Functionally Graded Materials (Adv. Funct. Mater. 32/2024)

From Grayscale Photopolymerization 3D Printing to Functionally Graded Materials (Adv. Funct. Mater. 32/2024)

Digital Light Processing to Afford High Resolution and Degradable CO2‐Derived Copolymer Elastomers

AbstractVat photopolymerization 3D printing has proven very successful for the rapid additive manufacturing (AM) of polymeric parts at high resolution. However, the range of materials that can be printed and their resulting properties remains narrow. Herein, we report the successful AM of a series of poly(carbonate‐b‐ester‐b‐carbonate) elastomers, derived from carbon dioxide and bio‐derived ϵ‐decalactone. By employing a highly active and selective Co(II)Mg(II) polymerization catalyst, an ABA triblock copolymer (Mn=6.3 kg mol−1, ÐM=1.26) was synthesized, formulated into resins which were 3D printed using digital light processing (DLP) and a thiol‐ene‐based crosslinking system. A series of elastomeric and degradable thermosets were produced, with varying thiol cross‐linker length and poly(ethylene glycol) content, to produce complex triply periodic geometries at high resolution. Thermomechanical characterization of the materials reveals printing‐induced microphase separation and tunable hydrophilicity. These findings highlight how utilizing DLP can produce sustainable materials from low molar mass polyols quickly and at high resolution. The 3D printing of these functional materials may help to expedite the production of sustainable plastics and elastomers with potential to replace conventional petrochemical‐based options.

Digital Light Processing to Afford High Resolution and Degradable CO2-Derived Copolymer Elastomers.

Vat photopolymerization 3D printing has proven very successful for the rapid additive manufacturing (AM) of polymeric parts at high resolution. However, the range of materials that can be printed and their resulting properties remains narrow. Herein, we report the successful AM of a series of poly(carbonate-b-ester-b-carbonate) elastomers, derived from carbon dioxide and bio-derived ϵ-decalactone. By employing a highly active and selective Co(II)Mg(II) polymerization catalyst, an ABA triblock copolymer (Mn=6.3 kg mol-1, ÐM=1.26) was synthesized, formulated into resins which were 3D printed using digital light processing (DLP) and a thiol-ene-based crosslinking system. A series of elastomeric and degradable thermosets were produced, with varying thiol cross-linker length and poly(ethylene glycol) content, to produce complex triply periodic geometries at high resolution. Thermomechanical characterization of the materials reveals printing-induced microphase separation and tunable hydrophilicity. These findings highlight how utilizing DLP can produce sustainable materials from low molar mass polyols quickly and at high resolution. The 3D printing of these functional materials may help to expedite the production of sustainable plastics and elastomers with potential to replace conventional petrochemical-based options.

Dimethyl sulfoxide mediated high-fidelity 3D printing of hydrogels

Owing to flexible structural design and rapid prototyping manufacturing, 3D printable hydrogels with solid-like and fluid-like characters have emerged as a promising candidate for biomedical engineering, soft robotics, and flexible electronics. However, existing 3D printing of hydrogel place substantial constraints on hydrogel high-fidelity of the printed hydrogel complex structures due to the shape deformation and collapse caused by water evaporation. Herein, we propose a mixed solvent printing strategy followed with water dialysis to achieve vat photopolymerization 3D printing of high-fidelity hydrogel structure by restraining water evaporation. Concretely, dimethyl sulfoxide (DMSO) is introduced into the hydrogel ink as co-solvent to improve the anti-dehydration performance during 3D printing. The as-prepared gels are then transformed into hydrogels with good fidelity and excellent performance through solvent exchange and water dialysis. Enabled by these characteristics, various functional devices with complex structures are demonstrated with the present high-fidelity 3D printing of diverse hydrogels. The solvent assisted high-fidelity hydrogel 3D printing protocol combining with the compatibility to various high-performance hydrogels is believed to be promising for wearable devices, wound dressings, electronic skin, and intelligent robots.

Vat photopolymerization 3D printing of biobased low viscosity photoactive benzoxazine thermosets

Preparing biobased benzoxazine resin through vat photopolymerization 3D printing is of great significance for its sustainable development and application in cutting-edge fields. In this work, biobased guaiacol and eugenol are used as phenol sources, while 2-(2-aminoethoxy) ethanol with flexible ether bonds is used as an amine source to create photoactive benzoxazine monomers, Eu-BzMA and Gu-BzMA. The viscosity of both monomers at room temperature is lower than 150 mPa·s, which can satisfy the requirements of digital light processing (DLP) 3D printing without adding diluents. The thermal and mechanical properties of the 3D printing benzoxazine resins are studied and the relationship between structure and properties is discussed by comparing the two molecules. Eu-BzMA resin has higher thermal decomposition temperature (T5 = 343 °C), higher hardness (0.70 GPa), higher flexural stress (43.5 MPa) and flexural moduli (2.71 GPa); while, Gu-BzMA resin has higher glass transition temperature (176 °C). This is because Eu-BzMA resin shows higher cross-linking density, but contains more flexible structures formed by allyl crosslinking. In this article, a preparation strategy of low viscosity biobased photoactive benzoxazine is proposed and successfully applied to vat photopolymerization 3D printing.

High-precision BaTiO3 piezoelectric ceramics via vat photopolymerization 3D printing

BaTiO3 ceramics with high precision and superior performance are fabricated by vat photopolymerization 3D printing technology. The curing behaviors and photosensitive mechanisms are systematically investigated. Through the optimization of printing parameters, BaTiO3 ceramics with a high relative density of 95 % and few defects are obtained. Notably, the sintered BaTiO3 ceramics exhibit impressive properties, including a high piezoelectric coefficient d33 of 201 pC/N and strong ferroelectric characteristics with a maximum polarization Pmax of 31.4 μC/cm2 and residual polarization Pr of 18.5 μC/cm2. More importantly, a series of complex BaTiO3 structures including the body-centered cubic lattice and triply periodic minimal surface (TPMS) structures are created perfectly with the feature size as fine as 75 μm. Compared with other reported BaTiO3 structures printed by vat photopolymerization and material extrusion technologies, this work realizes a much higher printing resolution. The excellent performance and high precision of these BaTiO3 ceramics make them great potential for practical applications in piezoelectric components.

Mechanical and dielectric properties of Si3N4/β-SiAlON composite ceramics fabricated by vat photopolymerization 3D printing technology

Vat photopolymerization 3D printing provides a novel approach for preparing broadband wave-transparent Si3N4/β-SiAlON composite ceramics. This paper oxidized raw powder to introduce low dielectric phases (SiO2) and overcome the low curing depth of α-Si3N4. The solid content of oxidized α-Si3N4 was increased to 50 vol% for the first time by modification with dispersant. The selected print thickness of 50 μm was the highest known for Si3N4 vat photopolymerization 3D printing, greatly improving printing efficiency. Finally, Si3N4/β-SiAlON composite ceramics were sintered in the range of 1600-1800 °C, and the mechanical and dielectric properties were systematically studied. The composite ceramics sintering at 1780 °C had a maximum bending strength of 236 ± 16 MPa, and the real permittivity was 4.83. At 1800 °C the porosity increased resulting in bending strength decreased to 109 ± 4 MPa, and the real permittivity to 3.23. This study filled the gap in the post-treatment of oxidized α-Si3N4 and guided the application of Si3N4/β-SiAlON composite ceramics in the field of wave-transparent.

How to Improve the Curing Ability during the Vat Photopolymerization 3D Printing of Non-Oxide Ceramics: A Review.

Vat photopolymerization (VP), as an additive manufacturing process, has experienced significant growth due to its high manufacturing precision and excellent surface quality. This method enables the fabrication of intricate shapes and structures while mitigating the machining challenges associated with non-oxide ceramics, which are known for their high hardness and brittleness. Consequently, the VP process of non-oxide ceramics has emerged as a focal point in additive manufacturing research areas. However, the absorption, refraction, and reflection of ultraviolet light by non-oxide ceramic particles can impede light penetration, leading to reduced curing thickness and posing challenges to the VP process. To enhance the efficiency and success rate of this process, researchers have explored various aspects, including the parameters of VP equipment, the composition of non-oxide VP slurries, and the surface modification of non-oxide particles. Silicon carbide and silicon nitride are examples of non-oxide ceramic particles that have been successfully employed in VP process. Nonetheless, there remains a lack of systematic induction regarding the curing mechanisms and key influencing factors of the VP process in non-oxide ceramics. This review firstly describes the curing mechanism of the non-oxide ceramic VP process, which contains the chain initiation, chain polymerization, and chain termination processes of the photosensitive resin. After that, the impact of key factors on the curing process, such as the wavelength and power of incident light, particle size, volume fraction of ceramic particles, refractive indices of photosensitive resin and ceramic particles, incident light intensity, critical light intensity, and the reactivity of photosensitive resins, are systematically discussed. Finally, this review discusses future prospects and challenges in the non-oxide ceramic VP process. Its objective is to offer valuable insights and references for further research into non-oxide ceramic VP processes.