An acoustic liquefaction approach to enhance the flow of yield stress fluids during Digital Light Processing (DLP)‐based 3D printing is reported. This enhanced flow enables processing of ultrahigh‐viscosity resins (μapp > 3700 Pa s at shear rates = 0.01 s–1) based on silica particles in a silicone photopolymer. Numerical simulations of the acousto–mechanical coupling in the DLP resin feed system at different agitation frequencies predict local resin flow velocities exceeding 100 mm s–1at acoustic transduction frequencies of 110 s–1. Under these conditions, highly loaded particle suspensions (weight fractions, ϕ = 0.23) can be printed successfully in complex geometries. Such mechanically reinforced composites possess a tensile toughness 2000% greater than the neat photopolymer. Beyond an increase in processible viscosities, acoustophoretic liquefaction DLP (AL‐DLP) creates a transient reduction in apparent viscosity that promotes resin recirculation and decreases viscous adhesion. As a result, acoustophoretic liquefaction Digital Light Processing (AL‐DLP) improves the printed feature resolution by more than 25%, increases printable object sizes by over 50 times, and can build parts >3 × faster when compared to conventional methodologies.
The availability of engineering polymers for vat photopolymerization (VP) additive manufacturing is limited. This limitation primarily stems from the inability of standard VP systems to recoat high-viscosity resins (> 3 Pa s). High-temperature vat photopolymerization is a new process-based VP platform that enables processing of viscous photopolymer resins (viscosity > 3 Pa s). Research in this area has been focused on demonstrating expanded access to new polymer families, and studying the effect of printing temperature on mechanical and esthetic performance of printed parts. However, methods to determine the printing temperature that prevents the occurrence of thermally induced polymerization (i.e., thermal stability) in the resin have not been established. In this work, the authors have applied characterization techniques such as thermogravimetric analysis, Rheology and differential scanning calorimetry to determine the printing temperature for processing viscous photopolymer resins. As a case study, the developed characterization techniques are applied to: (1) photopolymer that is solid at room temperature, (2) polymer with viscosity of 21 Pa s at room temperature, and the temperature at which the resins can be printed without triggering thermally induced polymerization is successfully determined. The results of this work will act as a materials’ characterization and process parameter development guide for high-temperature VP systems, thus enabling expansion of VP materials catalogue to engineering materials that were previously unprocessable.
more » « less- NSF-PAR ID:
- 10491666
- Publisher / Repository:
- Springer Science + Business Media
- Date Published:
- Journal Name:
- Progress in Additive Manufacturing
- ISSN:
- 2363-9512
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract Vat photopolymerization (VP) and direct ink write (DIW) additive manufacturing (AM) provide complex geometries with precise spatial control employing a vast array of photo‐reactive polymeric systems. Although VP is recognized for superior resolution and surface finish, DIW provides versatility for higher viscosity systems. However, each AM platform presents specific rheological requirements that are essential for successful 3D printing. First, viscosity requirements constrain VP polymeric materials to viscosities below 10 Pa s. Thus, this requirement presents a challenging paradox that must be overcome to attain the physical performance of high molecular weight polymers while maintaining suitable viscosities for VP polymeric materials. Second, the necessary rheological complexity that is required for DIW pastes requires additional rheological measurements to ensure desirable thixotropic behavior. This manuscript describes the importance of rheological measurements when designing polymeric latexes for AM. Latexes effectively decouple the dependency of viscosity on molecular weight, thus enabling high molecular weight polymers with low viscosities. Photo‐crosslinking of water‐soluble monomers and telechelic oligomeric diacrylates in the presence of the latex enables the fabrication of a scaffold, which is restricted to the continuous aqueous phase and effectively surrounds the latex nanoparticles enabling the printing of otherwise inaccessible high molecular weight polymers. Rheological testing, including both steady and oscillatory shear experiments, provides insights into system properties and provides predictability for successful printing. This perspective article aims to provide an understanding of both chemical functionality (photo‐ and thermal‐reactivity) and rheological response and their importance for the successful design and evaluation of VP and DIW processable latex formulations.
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3D‐printed polymer blends with programmable mechanical and compositional heterogeneity were fabricated using grayscale digital light processing by spatially modulating the intensity of light during printing and swelling the resulting part with a second monomer. A rubbery poly(ethylene glycol) diacrylate functionally graded print is variably swollen with acrylamide monomer as a function of crosslinking density. Following a secondary polymerization, a 3D‐printed functionally graded blend with regions of varying composition and stiffness was formed. A deterministic model for polymer conversion informs printing conditions to correspond with predicted material properties based upon local volume fractions of the two materials. Upon the secondary polymerization, two networks are present within the printed structure including glassy and rubbery regions. The compressive moduli of local regions within prints ranges from 76 to 200 MPa and measured moduli of the structures agree with predicted values acquired using finite element analysis. A lattice structure with prescribed local stiffness printed using grayscale exposures deforms differentially when compressed. Advantageously, local dimensional deformations caused by the removal of the unreacted printing monomer are eliminated due to the introduction of the second polymer. This method provides predictive control over local mechanical properties and high shape precision while maintaining the simplicity of vat photopolymerization.
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