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Increasing Printable Solid Loading in Digital Light Processing Using a Bimodal Particle Size Distribution.

Antoine P Delarue1, Ian M McAninch2, Amy M Peterson3

  • 1Department of Mechanical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA.

3D Printing and Additive Manufacturing
|January 1, 2025
PubMed
Summary
This summary is machine-generated.

Digital light processing (DLP) additive manufacturing can now achieve higher filler content using bimodal particle size distributions. This enables printing of high-resolution composite structures with up to 70 vol% fillers.

Keywords:
bimodaldigital light processingfillerhighly filledparticle size distribution

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Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Polymer Chemistry

Background:

  • Digital light processing (DLP) is a popular additive manufacturing technique for composite structures.
  • High filler content in DLP resins increases viscosity, limiting applications.
  • Maximizing filler content is crucial for advanced composite material properties.

Purpose of the Study:

  • To investigate bimodal particle size distributions for high-filler-content DLP resins.
  • To determine the effect of particle distribution on resin viscosity and printability.
  • To evaluate the achievable resolution of highly filled DLP-printed parts.

Main Methods:

  • Formulation of photosensitive resins with varying unimodal and bimodal filler loadings (50–72 vol%).
  • Rheological analysis using rotational rheometry to measure viscoelastic properties.
  • Krieger-Dougherty model fitting to determine particle packing fractions.
  • Fabrication and resolution testing of printed parts with fine features.
  • Thermogravimetric analysis to assess filler content stability during printing.

Main Results:

  • Bimodal particle size distribution enables printing of resins with up to 70 vol% fillers.
  • Zero-shear viscosity was modeled using the Krieger-Dougherty equation, yielding a dense random close packing fraction of 76.3 vol%.
  • High-resolution parts were printed, with features as small as 380 μm (positive) and 860 μm (negative) at 70 vol% loading.
  • Filler content remained stable during printing, with only a 2 vol% decrease in solids for the final layers.

Conclusions:

  • Bimodal particle size distributions significantly enhance the filler loading capacity of DLP resins.
  • This approach overcomes viscosity limitations, enabling high-performance composite fabrication via DLP.
  • The study demonstrates the feasibility of printing complex, high-resolution parts with substantially increased filler content.