Tailoring UV Penetration Depth in Photopolymer Nanocomposites: Advancing SLA 3D Printing Performance with Nanofillers

This study examines the influence of nanofillers on the ultraviolet (UV) penetration depth of photopolymer resins used in stereolithography (SLA) 3D printing, and their impact on printability. Three nanofillers, multiwalled carbon nanotubes (MWCNT), graphene nanoplatelets (xGNP), and boron nitride nanoparticles (BNNP), were incorporated into a commercially available photopolymer resin to prepare nanocomposite formulations. The UV penetration depth (Dp) was assessed using the Windowpane method, revealing a significant reduction with the addition of nanofillers. At a concentration of 0.25 wt.%, MWCNT showed the highest reduction in Dp (90%), followed by xGNP (65%) and BNNP (33%). SLA 3D printing was performed at varying nanofiller concentrations to evaluate printability. The findings highlight a strong correlation between Dp and the maximum printable nanofiller concentration, with MWCNT limiting printability to 0.05 wt.% due to its low Dp, while BNNP allowed printing up to 1.5 wt.%. Mechanical testing showed substantial improvements in hardness and elastic modulus, even at low nanofiller concentrations, with BNNP outperforming other fillers. Compared to a clear photopolymer, the elastic modulus for 3D printed nanocomposite samples with 0.05 wt.% nanofiller compositions showed an improvement of 43% for MWCNT, 63% for xGNP, and 104% for BNNP. The hardness results showed an improvement of 86% for MWCNT, 103% for xGNP, and 179% for BNNP. These results underscore the importance of Dp in determining the layer thickness and print success in SLA 3D printing. Practical applications include the design of advanced photopolymer nanocomposites for biomedical devices, electronics, and lightweight structural components. This research provides valuable insights for tailoring material properties to meet the demands of high-performance additive manufacturing.