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High-Strength, Lightweight TPMS Structures from Surface-Modified Coal-Based Solid Waste Glass Powder by DLP
1Department of Materials Science and Engineering, University of Science & Technology Beijing, Beijing 100083, China.
Langmuir : the ACS Journal of Surfaces and Colloids
|November 19, 2025
Summary
This study transforms coal waste into high-performance 3D printed structures using digital light processing. Modified coal glass powder enables lightweight, strong triply periodic minimal surface (TPMS) designs for advanced engineering applications.
Area of Science:
- Materials Science
- Additive Manufacturing
- Waste Valorization
Background:
- Coal-based solid waste poses environmental challenges.
- High costs of 3D printing raw materials limit applications.
- Need for sustainable industrial waste utilization strategies.
Purpose of the Study:
- To develop high-value applications for coal-based solid waste.
- To fabricate lightweight, high-performance triply periodic minimal surface (TPMS) structures.
- To utilize digital light processing (DLP) 3D printing for waste repurposing.
Main Methods:
- Coal-based solid waste glass powder (CWGP) was modified using silane coupling agents (KH550, KH560, KH570).
- Modified CWGP was incorporated into a 1,6-hexanediol diacrylate (HDDA) resin system for 3D printing.
- Digital light processing (DLP) 3D printing was used to fabricate complex TPMS architectures.
- Mechanical properties of the printed structures were evaluated.
Main Results:
- Silane coupling agent modification, particularly with KH570, enhanced CWGP's hydrophobic properties (water contact angle: 97.1°).
- Modified powder improved slurry dispersion and reduced viscosity (0.032 Pa·s at 30 s-1), ensuring excellent stability and printability.
- Five TPMS architectures (Gyroid, Schwarz, Diamond, Lidinoid, Split-P) were successfully printed.
- The Split-P TPMS structure achieved a maximum compressive strength of 12.81 MPa.
Conclusions:
- Modified coal waste glass powder is a viable filler for DLP 3D printing resins.
- Lightweight, high-performance TPMS structures can be fabricated from industrial solid waste.
- This approach offers a sustainable method for waste valorization and advanced material development for aerospace and rail transit.
