Multicomponent Acrylic Formulation Design for Corrosion Casting with Controlled Mechanical Properties

Corrosion casting based on the curing of acrylic resins enables one to create casts as replicas of body systems, enhancing our knowledge of veterinary medicine. The identification of the optimal chemical formulations as well as the processing conditions, the delivery of good control during the liquid state and the excellent macroscopic properties during solidification and after use are remaining challenges. In the present work, based on the identification of more qualitative trends, it is demonstrated that multicomponent comonomer mixtures are interesting materials that can be used to expand the range of mechanical properties and can specifically result in a better balance between stiffness and flexibility while guaranteeing dimensional stability. Emphasis is put on a large pool of formulations in the testing phase to then perform a detailed mechanical flexural analysis for the most promising cases during a more rigorous testing phase, accounting for a new pragmatic protocol for the pot life. This protocol consists of a vial-based turning test and a measurement of the viscosity variation up to 1000 mPa∙s and highlights the complex interplay between the overall initial concentrations and the impact of the absence of mixing once the system is at rest. It is demonstrated that the use of only low-molar-mass crosslinkers should be avoided, and overall, an intermediate amount of crosslinkers is recommendable.