Resin Blends Research Articles

Bio-Based Epoxy-Phthalonitrile Resin: Preparation, Characterization, and Properties.

Preparation of high-performance thermosetting resins via bio-based resources is important for the development of a sustainable world. In this work, we proposed the introduction of cyanide structure groups into the molecular structure of epoxy resins to give them excellent heat resistance. A eugenol-based epoxy-phthalonitrile (EEPN) resin was synthesized by a two-step process using the bio-based renewable resource of eugenol, and a series of EEPN/Epoxide resin (E51) blend resins with different EEPN contents were prepared. The structure of the EEPN monomer was characterized and confirmed by Fourier transform infrared (FTIR), nuclear magnetic resonance (NMR), and elemental analysis. The thermal stability and dynamic mechanical properties of the cured resins were investigated by thermogravimetric analysis and dynamic mechanical thermal analysis. The experimental results showed that EEPN had excellent heat resistance; the char yield at 800 °C was 67.9 wt%, which was much higher than that of E51 at 26.3 wt%; and the heat resistance of the blended resins was significantly improved with the increase in the EEPN content.

Hybrid direct ink writing of bioglass-calcite-carbon composite scaffolds supported by novel silicone-based emulsions

70S30C (70 mol% SiO2, 30% CaO) bioglass is one of the most promising bioceramics for bone tissue engineering. We discuss the feasibility of 70S30C bioglass/calcite/carbon composites derived from novel silicone-based emulsions, leading to highly porous lattice scaffolds. These are produced by direct ink writing (DIW) 3D printing, followed by ceramic conversion at 700°C in flowing nitrogen. The emulsions consisted of droplets of concentrated calcium nitrate aqueous solution incorporated into blends of H44 commercial polysiloxane and photocurable acrylate resin. This formulation offered unprecedented opportunities in both synthesis and shaping. Specifically, the homogeneous dispersion of the CaO precursor in silicone enabled a uniform SiO2/CaO distribution, favoring the formation of a glass matrix. Additionally, the acrylate component and water content allowed for tuning of the microstructure both immediately after printing and upon firing. Photopolymerization of acrylates consolidated the printed bodies (configuring a 'hybrid DIW') after extrusion, while water evaporation enhanced gas evolution during ceramic conversion, promoting pore interconnectivity.

Nano aluminum nitride fillers for enhanced mechanical and thermal properties of GFRP in cryogenic temperature settings

Glass fiber-reinforced polymer (GFRP) composites, with epoxy resin or a blend of cyanate and epoxy resins as the matrix, have been used as insulating materials of high-field, large-scale superconducting magnets for accelerators and magnetic confinement fusion. However, the GFRP does not fully meet the requirements for the next generation of magnetic confinement fusion with respect to the mechanical and thermal performance at cryogenic temperature and huge electromagnetic stress. This paper introduces a method for enhancing both the mechanical and thermal properties of the GFRP composites using aluminum nitride (AlN) nanoparticles. The fabrication of the AlN-GFRP composite involved a method that combines “dip absorption” with vacuum-assisted resin transfer molding (VARTM). The dip absorption method was utilized to deposit AlN nanopowders onto glass fibers, resulting in the preparation of AlN-glass fiber layers. Subsequently, the AlN-woven glass fibers were incorporated to reinforce the cyanate ester/epoxy based composites using the VARTM technology. The mechanical and thermal properties of the AlN-GFRP composites were assessed across varying temperatures. The results indicate that the short-beam shear strength (SBS strength) of the AlN-GFRP composites improves at cryogenic temperatures compared to that of the GFRP composites without AlN. Additionally, enhanced thermal conductivities are observed across different temperature ranges for the AlN-GFRP composites. The coefficient of thermal expansion between 77 K and 300 K of the composites significantly decreases with the addition of the AlN nanopowders.

Investigation on the Curing and Thermal Properties of Epoxy/Amine/Phthalonitrile Blend.

The bisphenol A-type phthalonitrile (BAPH) was blended with the classic epoxy system E51/DDS to prepare the epoxy/phthalonitrile thermoset. The curing kinetics were investigated by differential scanning calorimetry (DSC) using the isoconversional principle, and the average activation energy (Eα) of the E51/DDS curing reaction was found to decrease from 87 kJ/mol to 68.6 kJ/mol. Combining the results of the rheological study, the promoting effect of phthalonitrile on the crosslink of epoxy/amine is confirmed. The curing reaction of the blended resin was characterized using FTIR, and the results showed that BAPH could react with DDS. The thermal behaviors of the thermosets were investigated via DMA and TGA. The glass transition temperature (Tg) is found to increase from 181 °C to 195 °C. The char yield increases from 16% to 59.6% at 800 °C in a N2 atmosphere, which is higher than the calculated value based on the proportional principle. The AFM phase images show that there is no phase separation in the cured thermoset. The results imply that the cured epoxy/amine/phthalonitrile blend is probably a kind of copolymer. The real-time TG-MS indicated that the pyrolysis of the thermoset can be divided into two relatively independent stages, which can be assigned to the cleavage of the E51/DDS network, and the phthalocyanine/triazine/isoindoline, respectively.

Promotion on the thermal and mechanical behaviors of epoxy resin using phthalonitrile and functionalized‐SiO2

AbstractThe phenolic‐type phthalonitrile (PN) was added to EP/DDM system in order to enhance the thermal and mechanical performance at high temperature. The influence of the added PN on the curing process of EP/DDM was studied via DSC and the activating energy (Eα) was calculated based on iso‐conversional method. The Eα values corresponding to EP/DDM crosslink reaction remained at about 60 kJ mol−1 while it dramatically increased to 68.2 kJ mol−1 when PN content reached 50 wt% (EP‐PN50). The Tg and char yield at 700°C in N2 increased from141°C, 25.7%, for the neat EP/DDM to 226°C, 68.7% for the EP‐PN50. The measured char yields of the cured blend were higher than the calculated values which implies the interaction between EP/DDM and polyphthalonitrile network. The tensile and bending tests were carried out at 413 K and the modulus of EP‐PN50 remains 2.3 Gpa. On the meantime, the cyano‐functionalized SiO2 (CNSiO2) was prepared to further promote the mechanical behaviors of this resin blend in high temperature. The contact angles of raw SiO2, KH560SiO2, CNSiO2 with EP‐PN50 are 59.3, 52.6, 49.7°, respectively, which confirms the better wettability of CNSiO2 to the EP/PN blend. Furthermore, the tensile and bending tests conducted at 413 K confirmed that the CNSiO2 was more efficient on enhancing the mechanical performance of this EP/DDM/PN system at high temperature.

Preparation and performance control of ultra-low near-infrared reflectivity coatings with super-hydrophobic and outstanding mechanical properties

The development of ultra-low near-infrared reflectivity coatings with outstanding engineering properties remains a challenge in laser stealth materials research. Herein, we reported a laser stealth coating with outstanding mechanical properties, super-hydrophobicity, and an ultra-low near-infrared reflectivity for 1.06 μm wavelength. The effects of the mass ratio of graphene to nano-SiO2, the proportion of total filler, the addition of KH560, the mass ratio of Polydimethylsiloxane (PDMS) to acrylic-modified polyurethane (APU), and the addition of dioctyl phthalate (DOP) on the coating properties were thoroughly discussed. The coating can achieve a low reflectivity of 9.3% at 1.06 μm and a high water contact angle of 152° at a mass ratio of 7:3 for PDMS to APU and 6:4 for graphene to nano-SiO2 with a total filler amount of 40 wt%. KH560 can play a bridging role between the blended resin matrix and nano-SiO2, which can significantly improve the impact strength of the coating. The DOP, which contains a polar ester group and a non-polar carbon chain structure, can be inserted between the molecular chains of the resin to weaken the intermolecular force of the resin, so that the flexibility of the coating can be significantly improved. Adding KH560 at 4 wt% and DOP at 1 wt%, resulted in a coating with ultra-low near-infrared reflectivity of 1.06 μm (9.3%), super-hydrophobic properties, outstanding adhesion strength (grade 2), flexibility (2 mm), and impact strength (50 kg cm). The above super-hydrophobic ultra-low near-infrared reflectivity coating has significant potential for use in the field of laser stealth equipment, and it can serve as a useful reference for optimizing the mechanical properties of super-hydrophobic functional coatings.

Preparation and size control of epoxy resin multilevel structures with SiO2 particles

In the process of preparing porous epoxy materials using reaction-induced phase separation (RIPS), the introduction of an appropriate amount of SiO2 particles enables the control of the phase separation behavior of the system and its ultimate phase structure. This study examined the role of SiO2 particles in the preparation and size control of epoxy resin multilevel structures by analyzing the phase separation and reaction kinetics in an epoxy resin blend system and characterizing the ultimate phase structure. It was found that fumed SiO2 particles (0–3 wt%) added to the DGEBA/DDCM/PEG200 blends resulted in significant interfacial stabilization, delaying phase separation. With an increase in the fumed SiO2 particle content, the phase structure stopped evolving at an earlier stage of phase separation. In addition, the fumed SiO2 particles dispersed in the porogen-enriched phase helped to stabilize the system, i.e., preventing or slowing down the segregation and aggregation of the components in the system, which may inhibit secondary phase separation in the porogen-enriched phase. When 350 nm SiO2 particles were used, an increase in the particle size resulted in a larger phase structure. The SiO2 particles were dispersed within the pore-forming agent phase, increasing the proportion of the pore-forming agent and exerting an occupancy effect, which diminished with decreasing SiO2 particle size and increasing hydrophobicity. Notably, the surface of the epoxy porous material skeleton was decorated with small pits formed by the acid etching of the SiO2 particles, and this multilevel structure contributed to the specific surface area. The multilevel structure can be precisely controlled by adjusting the size, content, and wettability of the SiO2 particles. The results of this study are universal and instructive for the preparation of porous materials using a phase separation method in combination with solid particles.

Achieves Both Mechanical Properties and Hydrogen Permeability through Polymer Alloy Blend Resin Modification Technology

Achieves Both Mechanical Properties and Hydrogen Permeability through Polymer Alloy Blend Resin Modification Technology

Hybrid Solid Polymer Electrolytes Based on Epoxy Resins, Ionic Liquid, and Ceramic Nanoparticles for Structural Applications.

Solid polymer electrolytes (SPE) and composite polymer electrolytes (CPE) serve as crucial components in all-solid-state energy storage devices. Structural batteries and supercapacitors present a promising alternative for electric vehicles, integrating structural functionality with energy storage capability. However, despite their potential, these applications are hampered by various challenges, particularly in the realm of developing new solid polymer electrolytes that require more investigation. In this study, novel solid polymer electrolytes and composite polymer electrolytes were synthesized using epoxy resin blends, ionic liquid, lithium salt, and alumina nanoparticles and subsequently characterized. Among the formulations tested, the optimal system, designated as L70P30ILE40Li1MAl2 and containing 40 wt.% of ionic liquid and 5.7 wt.% of lithium salt, exhibited exceptional mechanical properties. It displayed a remarkable storage modulus of 1.2 GPa and reached ionic conductivities of 0.085 mS/cm at 60 °C. Furthermore, a proof-of-concept supercapacitor was fabricated, demonstrating the practical application of the developed electrolyte system.

Optimization and ranking of dental restorative composites by ENTROPY‐VIKOR and VIKOR‐MATLAB

AbstractResin‐based composites, now the most prevalent material for restorative dental treatments, are available in a multitude of types. Next‐generation composites are designed to be bio interactive, solving issues such as secondary caries and mechanical failures, thus prolonging the restoration lifespan. To facilitate the discrimination of the bio interactive composite's performance and the identification of the optimal composition, we tested the VIKOR method for multi‐criteria decision‐making analysis. This study encompassed 12 performance parameters and 5 experimental dental composites. We measured density, void content, water sorption, water solubility, polymerization shrinkage, depth of cure, degree of conversion, hardness, compressive strength, and surface roughness as performance parameters, and we tested a conventional BisGMA‐TEGDMA resin blend filled with yttria‐stabilized zirconia (20 wt.%) and tricalcium phosphate. The alignment between computational methods and MATLAB‐based calculations validated the robustness of the assessment, verifying the significance of the conclusions drawn from this comprehensive analysis. Both methods (ENTROPY‐VIKOR and VIKOR‐MATLAB) ranked TZC0 as the top composite. This research provided a comprehensive understanding of the complex relationship between material composition, performance attributes, and optimization strategies in dental restorative composites, offering valuable insights for future advancements in restorative dentistry.

In‐Situ Laser Synthesis of Molecularly Dispersed and Covalently Bound Phosphorus‐Graphene Adducts as Self‐Standing 3D Anodes for High‐Performance Fast‐Charging Lithium‐Ion Batteries

AbstractPhosphorus shows promise as a next‐generation anode material due to its high theoretical capacity of 2596 mAh g−1. However, challenges such as low conductivity, severe volume expansion, and the dissolution and migration of electrolyte‐soluble lithium polyphosphides hamper high‐performance capabilities. While carbon composites are widely researched as a solution through the physical encapsulation of micro‐nano‐phosphorus domains, anodes still exhibit low cycling stability and rate performance. In response, this work proposes a new approach, focusing on chemical anchoring and molecular dispersion of phosphorus within the carbon host. Through laser irradiation of a red phosphorus/phenolic resin blend, in‐situ covalent binding of molecular phosphorus adducts to the as‐forming laser‐induced graphene is observed; directly synthesizing an additive‐free, flexible and 3‐dimensional mesoporous composite anode with high phosphorus content (33 wt.%), specific surface area (163.4 m2 g−1) and intrinsic conductivity (12 S cm−1). These anodes demonstrate remarkable cycling stability, with capacity retention of 98% after 3000 cycles at a high current density of 2 A g−1 and capacity of 673 mAh g−1. The high cycling stability is further confirmed through the complete inhibition of lithium polyphosphide “shuttle effect” by chemical anchoring of the molecularly dispersed active material. Furthermore, scale‐up prospects utilizing laser‐assisted additive manufacturing are investigated.

Aromatic nitrile resins with improved processability and thermal properties prepared by collaborative design of structure and blending strategy

The contradiction between processability and thermal properties has been limiting the development of high-performance thermoset resins, especially aromatic nitrile resins (AN). A new AN resin blend of 2-(3-(3,4-dicyanophenoxy)phenyl)-1H-imidazole-4,5dicarbonitrile (PNDCI) and 4-(4-aminophenoxy) phthalonitrile (APN) named PAB based on Brønsted acid-base blending strategy and introduction of asymmetric structure was designed and prepared in this paper. A series of characterizations showed that the PAB has not only excellent processability with a diminished melting point (118°C), wider processing window (90°C), and high curing reactivity, but that the cured PAB resins (C-PAB) also possessed high glass transition temperature (477°C), excellent long-term thermo-oxidative stability, thermomechanical properties and dimensional stability. The present design strategy of blending resins provides PAB as a good reference material for achieving a good balance between processability and high-temperature resistance.

Green fabrication for ultra-lightweight polyethersulfone/epoxy foam with excellent thermal insulation

High-performance polymers find extensive applications in heat-resisting materials, aerospace, and automobile manufacturing industry. However, due to their challenging processability, achieving low-density high-performance polymer foams for thermal insulation materials remains a big challenge. Furthermore, the preparation of lightweight special engineering plastic foams has garnered substantial attention in current research. Herein, we have developed polyethersulfone (PES)/bisphenol A epoxy resin (EP) blend foams with ultra-low density and good thermal insulation properties using a facile and environmentally friendly supercritical CO2 (ScCO2) foaming approach. The inherent compatibility between PES and EP resin enhanced the free volume of molecular chain in the matrix, subsequently improving the solubility and diffusion rate of carbon dioxide within the PES matrix. Consequently, in contrast to the maximum expansion ratio of 5.5 observed in pure PES, the PES/EP blend foams achieved an expansion ratio of up to 26 times, along with an improvement of the cell structure of PES and increasing cell density from 2.55 × 109 to 2.96 × 1010 cells/cm3. Furthermore, the thermal conductivity of PES-based foams notably decreased from 0.0667 to 0.0348 W/(m·K) with the addition of EP, possibly resulting from the low density (0.05 g/cm3) and high open-cell content (79.9%) of PES/EP blend foam. Our work presents a novel strategy for producing special engineering plastic foams with ultra-low density for thermal insulation, thereby expanding the potential application of special engineering plastic foam in areas such as biological scaffolds, absorbent material applications, and automotive interior industry.

Preparation, Cure, Characterization, and Mechanical Properties of Reactive Flame-Retardant Cyanate Ester/Epoxy Resin Blends and their Carbon Fiber Reinforced Composites

This study explores the formulation space of flame retardant thermoset polymers, specifically involving blends of epoxy and cyanate ester (EP/CE) and a reactive phosphorus-based flame retardant, poly (m-phenylene methylphosphonate) (PMP). Two CE monomers were investigated, each blended with the same epoxy monomer (DGEBA) in a 1:1 wt ratio. The impact of phosphorus concentration on the neat (neat meaning no fibers were present) resin blends was characterized using differential scanning calorimetry (DSC) and thermogravimetric analysis (TGA). The flammability and mechanical characteristics were assessed using micro-combustion calorimetry (MCC) and dynamic mechanical analysis (DMA). Carbon fiber composite panels were successfully fabricated using a wet layup process and autoclave curing with a fiber volume fraction (Vf) of approximately 0.5. DMA testing of the cured composite laminates pinpointed that the average Tg of the EP/CE blend was reduced with PMP addition by up to 39 °C at a phosphorous level of 3 wt%. Cone calorimetry tests confirmed the effectiveness of the flame retardant by reducing the peak Heat Release Rate (HRR) by approximately 27 %. The integration of PMP into EP/CE only marginally reduced the 3-point flexural strength (6–15 %) and modulus (7–13 %) relative to baseline samples.

Antibacterial Properties of an Experimental Dental Resin Loaded with Gold Nanoshells for Photothermal Therapy Applications.

This study explored the chemical and antibacterial properties of a dental resin loaded with gold nanoshells (AuNPs) in conjunction with photothermal therapy (PTT) as a novel method against Streptococcus mutans (S. mutans) to prevent secondary caries. First, a 20-h minimum inhibitory concentration (MIC) assay was performed on solutions of AuNPs with planktonic S. mutans under an LED device and laser at 660 nm. Next, resin blends containing 0, 1 × 1010, or 2 × 1010 AuNPs/mL were fabricated, and the degree of conversion (DC) was measured using an FTIR spectroscopy. Lastly, a colony forming unit (CFU) count was performed following 24 h growth of S. mutans on 6 mm diameter resin disks with different light treatments of an LED device and a laser at 660 nm. The MIC results only showed a reduction in S. mutans at AuNP concentrations less than 3.12 µg/mL under a laser illumination level of 95.5 J/cm2 compared to the dark treatment (p < 0.010 for each). CFU and DC results showed no significant dependence on any light treatment studied. The AuNPs expressed antibacterial effects following PPT against planktonic S. mutans but not in a polymerized dental adhesive resin. Future studies should focus on different shapes, structure, and concentrations of AuNPs loaded in a resin blend.

Formation of Highly Robust Superhydrophobic Nanocomposite Coatings via Dual Spraying Technique

The development of materials that repel water, known as superhydrophobic materials, has been hindered by their vulnerability to mechanical abrasion. This issue is particularly pronounced for superhydrophobic nanocomposite coatings fabricated using a simple blend of resin and nanoparticles (NPs) through uncomplicated methods such as spraying or brushing, where an excessive amount of NPs can deteriorate the mechanical property. Moreover, the limitation of thickness puts forward a request for a high retention rate of the coatings. In response to these challenges, this study presents an innovative approach aimed at enhancing the robustness of superhydrophobic nanocomposite coatings through the utilization of a straightforward dual spraying technique. The results demonstrate that the particles with hierarchical micro/nanostructures fabricated by the primary spraying process provide abundant roughness feedstocks for the secondary‐sprayed coatings, in which superhydrophobicity properties can be achieved with less NP content. Additionally, the mechanical durability of the coatings can be reinforced by the addition of appropriate amounts of aluminum oxide (Al2O3) NPs and the continuous‐distributed particles fabricated by the primary‐spraying process, exhibiting a longer abrasion distance and a higher retention rate. Also, the prepared sample shows comprehensive robustness in adhesion, abrasion, and dynamic impact tests. By offering insights into material selection and process optimization, this study paves the way for creating resilient superhydrophobic coatings using a streamlined and convenient approach.

COMPATIBILITY STUDY OF HYDROCARBON RESINS WITH RUBBER COMPOUNDS FOR TIRE APPLICATIONS

ABSTRACT The addition of hydrocarbon resins to rubber compounds has a significant impact on their properties such as wet grip and rolling resistance. These performance characteristics have a strong correlation with the compatibility of the resin with the rubber matrix. Incompatible resins can cause excessive broadening of the damping curve, which results in poor rolling resistance. Compatibility, however, allows maximization of wet grip while minimizing the effect on rolling resistance. Compatibility is promoted by lower resin molecular weight and structural similarity to the polymers being blended. In this study, a method based on the Fox equation has been developed to quantitatively characterize the compatibility between resin and natural rubber (NR), a binary system. The dynamic shear rheometer (DSR), a tool new to the tire industry, is used to investigate the interaction between resin and two rubbers (i.e., a ternary system of NR–butadiene rubber [BR]–resin and solution polymerized styrene–butadiene rubber [SSBR]–butadiene rubber [BR]–resin), with a specific emphasis on resin partitioning among rubber blends. In addition, the DSR is applied to assess the Tg shift and tangent delta peak height, providing insight into the compatibility between rubbers and resin. A curve-fitting model was developed for the SSBR–BR–resin system to depict the relationship between these two parameters and the physical and chemical properties of resins, with the selection of resins featuring different degrees of aromaticity, Tg, and molecular weight. The findings indicated that higher Tg increased aromaticity and that lower molecular weight of the resin resulted in an elevated Tg shift in the blend, while lower molecular weight led to an increase in the tangent delta peak height. Our findings supply insight into the performance of rubber–resin blends and introduce a new screening tool for characterizing these blends in their green state.

Dynamic mechanical response and deformation mechanism of poly (ε-caprolactone) (PCL) / epoxy resin(EP) shape memory polymer composites

The dynamic mechanical response and deformation mechanism of poly (ε-caprolactone) (PCL) and epoxy resins shape memory polymer (SMP) composites were investigated in this paper. The SMP composites were a blend of PCL and epoxy resins by using the facile melt-mixing method. The distribution of PCL in the composites was observed by SEM, which was in from microparticle morphology to continuous morphology with the increasing PCL content. And the dynamic mechanical analyzer (DMA) tests were performed to demonstrate the viscoelastic properties and shape memory effect of the PCL/EP composites. Based on the above characterization of PCL/EP composites, the split Hopkinson pressure bar (SHPB) tests were performed to study the dynamic mechanical properties at the strain rates of 4000/s to 7000/s. The results showed that the flow stress increased with the increasing strain rate, which exhibited an obvious sensitivity to strain rate. However, the flow stress of PCL/EP decreases with the increasing PCL content due to the low strength of PCL. And PCL/EP composites failed in a typical ductile failure mode under quasi-static loading, whereas an excellent plastic deformation ability was observed at high strain rates, which was attributed to the heat generated by the plastic work during the adiabatic compression. Combining with the experimental results, the corresponding deformation mechanism was also discussed.

On color adjustment potential and color blending threshold of dental composite resins.

Color Adjustment Potential evaluates the color blending of dental Composite Resins. While Color Adjustment Potential is simple, its clinical relevance is unclear. This research aims to understand it better and to create an index for Composite Resins with meaningful clinical interpretation. Single and double shade composite disks of various diameters and opacities were created to test the indices. Color measurements used a dental colorimeter, avoiding subjective assessments. Color Adjustment Potential analysis of each material revealed insights, leading to the creation of a new Color Blending Threshold, providing a clinically relevant numerical value for Composite Resins. Color Adjustment Potential's numerical significance was clarified and introduced a new index for clinical applications. Color adaptation of each test shade to all Vita shades was also calculated, useful for single-shade restorations in open and closed cavity types. The proposed Color Blending Threshold defines the open/closed cavity dimension that can be adequately restored with a single shade of resin composite. Understanding how dental materials adapt to surrounding tooth colors enhances esthetic restorations, simplifies shade matching, and optimizes resin composite production. The proposed Color Blending Threshold is a parameter that directly relates to the clinical significance of a material's true color blending ability. It defines the cavity dimension that can be adequately restored with a single shade of resin composite while ensuring that the resulting color difference falls below a predetermined threshold, meeting the clinical requirements for an esthetic restoration.

Imiquimod nanocrystal-loaded dissolving microneedles prepared by DLP printing.

The utilization of 3D printing- digital light processing (DLP) technique, for the direct fabrication of microneedles encounters the problem of drug solubility in printing resin, especially if it is predominantly composed of water. The possible solution how to ensure ideal belonging of drug and water-based printing resin is its pre-formulation in nanosuspension such as nanocrystals. This study investigates the feasibility of this approach on a resin containing nanocrystals of imiquimod (IMQ), an active used in (pre)cancerous skin conditions, well known for its problematic solubility and bioavailability. The resin blend of polyethylene glycol diacrylate and N-vinylpyrrolidone, and lithium phenyl-2,4,6-trimethylbenzoylphosphinate as a photoinitiator, was used, mixed with IMQ nanocrystals in water. The final microneedle-patches had 36 cylindrical microneedles arranged in a square grid, measuring approximately 600μm in height and 500μm in diameter. They contained 5wt% IMQ, which is equivalent to a commercially available cream. The homogeneity of IMQ distribution in the matrix was higher for nanocrystals compared to usual crystalline form. The release of IMQ from the patches was determined ex vivo in natural skin and revealed a 48% increase in efficacy for nanocrystal formulations compared to the crystalline form of IMQ.