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Abstract 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.
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Toughening and Imparting Deconstructability to 3D‐Printed Glassy Thermosets with “Transferinker” Additives
Abstract Thermoset toughness and deconstructability are often opposing features; simultaneously improving both without sacrificing other mechanical properties (e.g., stiffness and tensile strength) is difficult, but, if achieved, could enhance the usage lifetime and end‐of‐life options for these materials. Here, a strategy that addresses this challenge in the context of photopolymer resins commonly used for 3D printing of glassy, acrylic thermosets is introduced. It is shown that incorporating bis‐acrylate “transferinkers,” which are cross‐linkers capable of undergoing degenerative chain transfer and new strand growth, as additives (5–25 mol%) into homemade or commercially available photopolymer resins leads to photopolymer thermosets with substantially improved tensile toughness and triggered chemical deconstructability with minimal impacts on Young's moduli, tensile strengths, and glass transition temperatures. These properties result from a transferinker‐driven topological transition in network structure from the densely cross‐linked long, heterogeneous primary strands of traditional photopolymer networks to more uniform, star‐like networks with few dangling ends; the latter structure more effectively bear stress yet is also more easily depercolated via solvolysis. Thus, transferinkers represent a simple and effective strategy for improving the mechanical properties of photopolymer thermosets and providing a mechanism for their triggered deconstructability.
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- Award ID(s):
- 2116298
- PAR ID:
- 10641310
- Publisher / Repository:
- Wiley Blackwell (John Wiley & Sons)
- Date Published:
- Journal Name:
- Advanced Materials
- Volume:
- 36
- Issue:
- 44
- ISSN:
- 0935-9648
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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