Cost-Effectively 3D-Printed Rigid and Versatile Interpenetrating Polymer Networks.

Area of Science:

• Polymer Science
• Materials Science
• Additive Manufacturing

Background:

• Acrylate-epoxy hybrid formulations are increasingly used in dual-photo/thermal-curing processes.
• 3D printing, particularly stereolithography and digital light processing (DLP), benefits from materials with tunable properties.
• Phase segregation in hybrid networks can negatively impact material performance.

Purpose of the Study:

• To formulate and characterize a novel acrylate-epoxy hybrid system for 3D printing.
• To investigate the effect of a coupling agent on phase segregation within the hybrid network.
• To explore the material's potential for shape programmability and repairable 3D printed structures.

Main Methods:

• Formulation of a hybrid resin using commercial acrylate and an epoxy-anhydride mixture.
• Addition of a coupling agent to mitigate epoxy-rich phase segregation.
• Characterization of mechanical properties (Young's modulus) and thermal curing behavior.
• Demonstration of shape molding, programmable shape recovery, and covalent joining of printed parts.

Main Results:

• The hybrid formulation exhibited improved Young's modulus compared to neat acrylate.
• The coupling agent effectively reduced phase segregation of epoxy-rich nano-domains.
• The material demonstrated successful molding, shape programmability with shape recovery at mild temperatures.
• Two separately printed halves were seamlessly joined via covalent bonding during thermal curing.

Conclusions:

• The developed acrylate-epoxy hybrid system offers enhanced mechanical properties and controlled phase behavior for 3D printing.
• The material's ability to be molded and its shape-memory characteristics open possibilities for complex, reconfigurable structures.
• The successful covalent joining of printed components highlights potential for creating larger, repairable 3D printed objects.