Vat photopolymerization-based 3D printing of polymer nanocomposites: current trends and applications

The synthesis and manufacturing of polymer nanocomposites have garnered interest in recent research and development because of their superiority compared to traditionally employed industrial materials. Specifically, polymer nanocomposites offer higher strength, stronger resistance to corrosion or erosion, adaptable production techniques, and lower costs. The vat photopolymerization (VPP) process is a group of additive manufacturing (AM) techniques that provide the benefit of relatively low cost, maximum flexibility, high accuracy, and complexity of the printed parts. In the past few years, there has been a rapid increase in the understanding of VPP-based processes, such as high-resolution AM methods to print intricate polymer parts. The synergistic integration of nanocomposites and VPP-based 3D printing processes has opened a gateway to the future and is soon expected to surpass traditional manufacturing techniques. This review aims to provide a theoretical background and the engineering capabilities of VPP with a focus on the polymerization of nanocomposite polymer resins. Specifically, the configuration, classification, and factors affecting VPP are summarized in detail. Furthermore, different challenges in the preparation of polymer nanocomposites are discussed together with their pre- and post-processing, where several constraints and limitations that hinder their printability and photo curability are critically discussed. The main focus is the applications of printed polymer nanocomposites and the enhancement in their properties such as mechanical, biomedical, thermal, electrical, and magnetic properties. Recent literature, mainly in the past three years, is critically discussed and the main contributing results in terms of applications are summarized in the form of tables. The goal of this work is to provide researchers with a comprehensive and updated understanding of the underlying difficulties and potential benefits of VPP-based 3D printing of polymer nanocomposites. It will also help readers to systematically reveal the research problems, gaps, challenges, and promising future directions related to polymer nanocomposites and VPP processes.

Dispersibility Characterization of Cellulose Nanocrystals in Polymeric-Based Composites

Cellulose nanocrystals (CNCs) are hydrophilic nanoparticles extracted from biomass with properties and functions different from cellulose and are being developed for property-oriented applications such as high stiffness, abundant active groups, and biocompatibility. It has broad application prospects in the field of composite materials, while the dispersibility of the CNC in polymers is the key to its application performance. Many reviews have discussed in-depth the modification strategies to improve the dispersibility of the CNC and summarized all characterization for the CNC, but there are no reviews on the in-depth exploration of dispersion characterization. This review is a comprehensive summary of the characterization of CNC dispersion in the matrix in terms of direct observation, indirect evaluation, and quantified evaluation, summarizing how and why different characterization tools reveal dispersibility. In addition, "decision tree" flowcharts are presented to provide the reader with a reference for selecting the appropriate characterization method for a specific composite.

An Overview of Natural Polymers as Reinforcing Agents for 3D Printing

Three-dimensional (3D) printing, or additive manufacturing, is a group of innovative technologies that are increasingly employed for the production of 3D objects in different fields, including pharmaceutics, engineering, agri-food and medicines. The most processed materials by 3D printing techniques (e.g., fused deposition modelling, FDM; selective laser sintering, SLS; stereolithography, SLA) are polymeric materials since they offer chemical resistance, are low cost and have easy processability. However, one main drawback of using these materials alone (e.g., polylactic acid, PLA) in the manufacturing process is related to the poor mechanical and tensile properties of the final product. To overcome these limitations, fillers can be added to the polymeric matrix during the manufacturing to act as reinforcing agents. These include inorganic or organic materials such as glass, carbon fibers, silicon, ceramic or metals. One emerging approach is the employment of natural polymers (polysaccharides and proteins) as reinforcing agents, which are extracted from plants or obtained from biomasses or agricultural/industrial wastes. The advantages of using these natural materials as fillers for 3D printing are related to their availability together with the possibility of producing printed specimens with a smaller environmental impact and higher biodegradability. Therefore, they represent a “green option” for 3D printing processing, and many studies have been published in the last year to evaluate their ability to improve the mechanical properties of 3D printed objects. The present review provides an overview of the recent literature regarding natural polymers as reinforcing agents for 3D printing.

Cellulose Nanocrystals vs. Cellulose Nanofibers: A Comparative Study of Reinforcing Effects in UV-Cured Vegetable Oil Nanocomposites

There is an opportunity to use nanocellulose as an efficient renewable reinforcing filler for polymer composites. There have been many investigations to prove the reinforcement concept of different nanocellulose sources for thermoplastic and thermoset polymers. The present comparative study highlighted the beneficial effects of selecting cellulose nanofibers (CNFs) and nanocrystals (CNCs) on the exploitation properties of vegetable oil-based thermoset composite materials—thermal, thermomechanical, and structural characteristics. The proposed UV-light-curable resin consists of an acrylated epoxidized soybean oil polymer matrix and two different nanocellulose reinforcements. High loadings of up to 30 wt% of CNFs and CNCs in irradiation-cured vegetable oil-based thermoset composites were reported. Infrared spectroscopy analysis indicated developed hydrogen-bonding interactions between the nanocellulose and polymer matrix. CNCs yielded a homogeneous nanocrystal dispersion, while CNFs revealed a nanofiber agglomeration in the polymer matrix, as shown by scanning electron microscopy. Thermal degradation showed that nanocellulose reduced the maximum degradation temperature by 5 °C for the 30 wt% CNC and CNF nanocomposites. Above the glass transition temperature at 80 °C, the storage modulus values increased 6-fold and 2-fold for the 30 wt% CNC and CNF nanocomposites, respectively. In addition, the achieved reinforcement efficiency factor r value for CNCs was 8.7, which was significantly higher than that of CNFs of 2.2. The obtained nanocomposites with enhanced properties show great potential for applications such as UV-light-processed coatings, adhesives, and additive manufacturing inks.

Recent advances in 3D printing of nanocellulose: structure, preparation, and application prospects

Emerging cellulose nanomaterials extracted from agricultural biomasses have recently received extensive attention due to diminishing fossil resources. To further reduce the carbon footprints and wastage of valuable resources, additive manufacturing techniques of new nanocellulosic materials have been developed. Studies on the preparation and characterization of 3D-printable functional nanocellulosic materials have facilitated a deeper understanding into their desirable attributes such as high surface area, biocompatibility, and ease of functionalization. In this critical review, we compare and highlight the different methods of extracting nanocellulose from biorenewable resources and the strategies for transforming the obtained nanocellulose into nanocomposites with high 3D printability. Optimistic technical applications of 3D-printed nanocellulose in biomedical, electronics, and environmental fields are finally described and evaluated for future perspectives.

Sustainable Photopolymers in 3D Printing: A Review on Biobased, Biodegradable, and Recyclable Alternatives

The global market for 3D printing materials has grown exponentially in the last decade. Today, photopolymers claim almost half of the material sales worldwide. The lack of sustainable resins, applicable in vat photopolymerization that can compete with commercial materials, however, limits the widespread adoption of this technology. The development of "green" alternatives is of great importance in order to reduce the environmental impact of additive manufacturing. This paper reviews the recent evolutions in the field of sustainable photopolymers for 3D printing. It highlights the synthesis and application of biobased resin components, such as photocurable monomers and oligomers, as well as reinforcing agents derived from natural resources. In addition, the design of biologically degradable and recyclable thermoset products in vat photopolymerization is discussed. Together, those strategies will promote the accurate and waste-free production of a new generation of 3D materials for a sustainable plastics economy in the near future.

Formulation of a Model Resin System for Benchmarking Processing-Property Relationships in High-Performance Photo 3D Printing Applications

A well-defined resin system is needed to serve as a benchmark for 3D printing of high-performance composites. This work describes the design and characterization of such a system that takes into account processability and performance considerations. The Grunberg-Nissan model for resin viscosity and the Fox equation for polymer T_g were used to determine proper monomer ratios. The target viscosity of the resin was below 500 cP, and the target final T_g of the cured polymer was 150 °C based on tan-δ peak from dynamic mechanical analysis. A tri-component model resin system, termed DA-2 resin, was determined and fully characterized. The printed polymer post-cure exhibited good thermal properties and high mechanical strength, but has a comparatively low fracture toughness. The model resin will be used in additive manufacturing of fiber reinforced composite materials as well as for understanding the fundamental processing-property relationships in light-based 3D printing.