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Balancing Functionality and Printability: High-Loading Polymer Resins for Direct Ink Writing.

Shelbie A Legett1, Xavier Torres1, Andrew M Schmalzer1

  • 1Los Alamos National Laboratory, Los Alamos, NM 87545, USA.

Polymers
|November 11, 2022
PubMed
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Developing new inks for direct ink writing (DIW) requires careful consideration of printability. This study found that strut diameter and spacing ratio significantly impact DIW printability, with silica- and metal-filled inks being more predictable than ceramic-filled ones.

Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Polymer Chemistry

Background:

  • Direct ink writing (DIW) enables rapid 3D printing but lacks diverse, functional inks.
  • Developing custom inks is crucial for expanding DIW applications.
  • Assessing ink "printability" is essential for successful fabrication.

Purpose of the Study:

  • To investigate the impact of filler composition, concentration, printing parameters, and lattice structure on the printability of novel polysiloxane-based DIW inks.
  • To explore the performance of inks with high filler loadings (50-70 wt%) of metallic, ceramic, and emulsion components.
  • To provide insights into the trade-offs between ink development, printability, and final material properties.

Main Methods:

  • Formulation of polysiloxane inks with varying metallic, ceramic, and emulsion fillers at high concentrations (50-70 wt%).
Keywords:
3D printabilityPDMSdirect ink writingfunctional resinslattice structurepowdered fillersrheologythermomechanical properties

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  • Systematic evaluation of printing parameters and lattice structures (e.g., strut diameter, spacing ratio, SC vs. FCT geometries).
  • Analysis of printability, part stiffness, and thermal stability of the fabricated 3D printed objects.

    • Main Results:

    • Strut diameter and spacing ratio were identified as the most influential factors on DIW material printability.
    • Silica- and metal-filled inks demonstrated more predictable printability compared to ceramic-filled inks.
    • Higher filler loadings and specific lattice geometries (SC) resulted in stiffer printed parts; metal-filled inks exhibited superior thermal stability.

    Conclusions:

    • The study highlights key factors influencing the printability and performance of high-filler-loaded DIW inks.
    • Findings offer guidance for developing custom, multifunctional inks for direct ink writing applications.
    • Understanding the interplay between ink formulation, printing parameters, and structural design is critical for optimizing 3D printed material performance.