Comparative Studies on Polyurethane Composites Filled with Polyaniline and Graphene for DLP-Type 3D Printing

Mechanical and Shape Memory Properties of Additively Manufactured Polyurethane (PU)/Halloysite Nanotube (HNT) Nanocomposites

This paper investigates the impact of halloysite nanotube (HNT) content on mechanical and shape memory properties of additively manufactured polyurethane (PU)/HNT nanocomposites. The inclusion of 8 wt% HNTs increases their tensile strength by 30.4% when compared with that of virgin PU at 44.75 MPa. Furthermore, consistently significant increases in tensile modulus, compressive strength and modulus, as well as specific energy absorption are also manifested by 47.2%, 34.0%, 125% and 72.7% relative to neat PU at 2.29 GPa, 3.88 MPa, 0.28 GPa and 0.44 kJ/kg respectively. However, increasing HNT content reduces lateral strain due to the restricted mobility of polymeric chains, leading to a decrease in negative Poisson's ratio (NPR). As such, shape recovery ratio and time of PU/HNT nanocomposites are reduced by 9 and 45% with the inclusion of 10 wt% HNTs despite an increasing shape fixity ratio up to 12% relative to those of neat PU.

Graphitic Carbon Nitride as Reinforcement of Photopolymer Resin for 3D Printing

Digital light processing (DLP) has the advantages of higher printing speed and product precision than other 3D printing technologies. However, DLP products have low mechanical strength owing to the inherent properties of photocurable materials. Graphitic carbon nitride (GCN), which is an abundant hydrogen bonding motif (-NH2, -NH), has low solubility in most solvents; thus, to use GCN as a reinforcement of the polymer matrix, optimal dispersion processes must be applied. In this study, GCN was proposed as a novel reinforcing material to improve the mechanical properties of photocurable epoxy acrylate (EA) resins for DLP. Herein, two-step (planetary mixing and ultrasonication) processes were applied to disperse GCN within EA, and the dispersion performance was identified by checking the degree of precipitation over time. To test the printability of the dispersed GCN/EA composites subjected to DLP 3D printing, cube specimens of GCN/EA composites were prepared, and the dispersed GCN/EA output had a low dimensional error of 0.3-1.3%, while the undispersed composite output showed larger dimensional errors of 27.7-36.2%. Additionally, in the mechanical test of the DLP-3D-printed sample (dispersed GCN/EA composite), the tensile strength and elastic modulus of the dispersed GCN/EA composite specimen were measured to be 75.56 MPa and 3396 MPa, respectively, which were improved by 22% (tensile strength) and 34% (modulus of elasticity) in relation to those of the neat EA specimen. This study is the first to use GCN as a reinforcement and manufacture a composite product for DLP with excellent performance (22% increased tensile strength) through the optimal dispersion of GCN. Considering the high mechanical performance, DLP products using the GCN/EA composites can be used in industries such as automobiles, shipbuilding, and aviation.

Investigation of the in vitro biological activities of polyethylene glycol-based thermally stable polyurethane elastomers

The intense urge to replace conventional polymers with ecofriendly monomers is a step towards green products. The novelty of this study is the extraction of starch from the biowaste of wheat bran (WB) and banana peel (BP) for use as a monomer in the form of chain extenders. For the synthesis of polyurethane (PU) elastomers, polyethylene glycol (PEG) bearing an average molecular weight Mn = 1000 g mol-1 was used as a macrodiol, which was reacted with isophorone diisocyanate (IPDI) to develop NCO-terminated prepolymer chains. These prepolymer chains were terminated with chain extenders. Two series of linear PU elastomers were prepared by varying the concentration of chain extenders (0.5-2.5 mol%), inducing a variation of 40 to 70 wt% in the hard segment (HS). Fourier-transform infrared (FTIR) spectroscopy confirmed the formation of urethane linkages. Thermal gravimetric analysis (TGA) showed a thermal stability of up to 250 °C. Dynamic mechanical analysis (DMA) revealed a storage modulus (E') of up to 140 MPa. Furthermore, the hemolytic activities of up to 8.97 ± 0.1% were recorded. The inhibition of biofilm formation was investigated against E. coli and S. aureus (%), which was supported by phase contrast microscopy.

Progress in Photocurable 3D Printing of Photosensitive Polyurethane: A Review

In recent years, as a class of advanced additive manufacturing (AM) technology, photocurable 3D printing has gained increasing attention. Based on its outstanding printing efficiency and molding accuracy, it is employed in various fields, such as industrial manufacturing, biomedical, soft robotics, electronic sensors. Photocurable 3D printing is a molding technology based on the principle of area-selective curing of photopolymerization reaction. At present, the main printing material suitable for this technology is the photosensitive resin, a composite mixture consisting of a photosensitive prepolymer, reactive monomer, photoinitiator, and other additives. As the technique research deepens and its application gets more developed, the design of printing materials suitable for different applications is becoming the hotspot. Specifically, these materials not only can be photocured but also have excellent properties, such as elasticity, tear resistance, fatigue resistance. Photosensitive polyurethanes can endow photocured resin with desirable performance due to their unique molecular structure including the inherent alternating soft and hard segments, and microphase separation. For this reason, this review summarizes and comments on the research and application progress of photocurable 3D printing of photosensitive polyurethanes, analyzing the advantages and shortcomings of this technology, also offering an outlook on this rapid development direction.

3D Printed Graphene and Graphene/Polymer Composites for Multifunctional Applications

Three-dimensional (3D) printing, alternatively known as additive manufacturing, is a transformative technology enabling precise, customized, and efficient manufacturing of components with complex structures. It revolutionizes traditional processes, allowing rapid prototyping, cost-effective production, and intricate designs. The 3D printed graphene-based materials combine graphene's exceptional properties with additive manufacturing's versatility, offering precise control over intricate structures with enhanced functionalities. To gain comprehensive insights into the development of 3D printed graphene and graphene/polymer composites, this review delves into their intricate fabrication methods, unique structural attributes, and multifaceted applications across various domains. Recent advances in printable materials, apparatus characteristics, and printed structures of typical 3D printing techniques for graphene and graphene/polymer composites are addressed, including extrusion methods (direct ink writing and fused deposition modeling), photopolymerization strategies (stereolithography and digital light processing) and powder-based techniques. Multifunctional applications in energy storage, physical sensor, stretchable conductor, electromagnetic interference shielding and wave absorption, as well as bio-applications are highlighted. Despite significant advancements in 3D printed graphene and its polymer composites, innovative studies are still necessary to fully unlock their inherent capabilities.

Co-Influence of Nanofiller Content and 3D Printing Parameters on Mechanical Properties of Thermoplastic Polyurethane (TPU)/Halloysite Nanotube (HNT) Nanocomposites

Thermoplastic polyurethane (TPU) belongs to a polyurethane family that possesses an elongation much higher than 300%, despite having low mechanical strength, which can be overcome by incorporating clay-based halloysite nanotubes (HNTs) as additives to manufacture TPU/HNT nanocomposites. This paper focuses on the co-influence of HNT content and 3D printing parameters on the mechanical properties of 3D printed TPU/HNT nanocomposites in terms of tensile properties, hardness, and abrasion resistance via fused deposition modelling (FDM). The optimum factor-level combination for different responses was determined with the aid of robust statistical Taguchi design of experiments (DoEs). Material characterisation was also carried out to evaluate the surface morphology, nanofiller dispersion, chemical structure, thermal stability, and phase behaviour corresponding to the DoE results obtained. It is evidently shown that HNT level and infill density play a significant role in impacting mechanical properties of 3D-printed TPU/HNT nanocomposites.

The Effect of Few-Layer Graphene on the Complex of Hardness, Strength, and Thermo Physical Properties of Polymer Composite Materials Produced by Digital Light Processing (DLP) 3D Printing

The results of studying the effect of particles of few-layer graphene (FLG) synthesized by self-propagating high-temperature synthesis (SHS) on the complex of strength and thermo physical properties of polymer composite products obtained by digital light processing (DLP) 3D printing are presented. It was discovered to achieve an increase in thermophysical and strength parameters of polymers modified by FLG compared with samples made on the unmodified base resin. This result was achieved due to low defectiveness, namely the absence of Stone-Wales defects in the structure of FLG due to the homogeneous distribution of FLG over the volume of the polymer in the form of highly dispersed aggregates. It was possible to increase hardness by 120%, bending strength by 102%, Charpy impact strength by 205%, and thermal conductivity at 25 °C by 572% at concentrations of few-layer graphene of no more than 2 wt. %.

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.

Lignin as a High-Value Bioaditive in 3D-DLP Printable Acrylic Resins and Polyaniline Conductive Composite

With increasing environmental awareness, lignin will play a key role in the transition from the traditional materials industry towards sustainability and Industry 4.0, boosting the development of functional eco-friendly composites for future electronic devices. In this work, a detailed study of the effect of unmodified lignin on 3D printed light-curable acrylic composites was performed up to 4 wt.%. Lignin ratios below 3 wt.% could be easily and reproducibly printed on a digital light processing (DLP) printer, maintaining the flexibility and thermal stability of the pristine resin. These low lignin contents lead to 3D printed composites with smoother surfaces, improved hardness (Shore A increase ~5%), and higher wettability (contact angles decrease ~19.5%). Finally, 1 wt.% lignin was added into 3D printed acrylic resins containing 5 wt.% p-toluensulfonic doped polyaniline (pTSA-PANI). The lignin/pTSA-PANI/acrylic composite showed a clear improvement in the dispersion of the conductive filler, reducing the average surface roughness (R_a) by 61% and increasing the electrical conductivity by an order of magnitude (up to 10^-6 S cm^-1) compared to lignin free PANI composites. Thus, incorporating organosolv lignin from wood industry wastes as raw material into 3D printed photocurable resins represents a simple, low-cost potential application for the design of novel high-valued, bio-based products.

Characterization 0.1 wt.% Nanomaterial/Photopolymer Composites with Poor Nanomaterial Dispersion: Viscosity, Cure Depth and Dielectric Properties

Notably, 3D printing techniques such as digital light processing (DLP) have the potential for the cost-effective and flexible production of polymer-based piezoelectric composites. To improve their properties, conductive nanomaterials can be added to the photopolymer to increase their dielectric properties. In this study, the microstructure, viscosity, cure depth, and dielectric properties of ultraviolet (UV) light curable 0.1 wt.% nanomaterial/photopolymer composites are investigated. The composites with multi-walled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), and carbon black (CB) are pre-dispersed in different solvents (acetone, isopropyl alcohol, and ethanol) before adding photopolymer and continuing dispersion. For all prepared suspensions, a reduction in viscosity is observed, which is favorable for 3D printing. In contrast, the addition of 0.1 wt.% nanomaterials, even with poor dispersion, leads to curing depth reduction up to 90% compared to pristine photopolymer, where the nanomaterial dispersion is identified as a contributing factor. The formulation of MWCNTs dispersed in ethanol is found to be the most promising for increasing the dielectric properties. The post-curing of all composites leads to charge immobility, resulting in decreased relative permittivity.

Recent Advances on 2D Materials towards 3D Printing

In recent years, 2D materials have been implemented in several applications due to their unique and unprecedented properties. Several examples can be named, from the very first, graphene, to transition-metal dichalcogenides (TMDs, e.g., MoS2), two-dimensional inorganic compounds (MXenes), hexagonal boron nitride (h-BN), or black phosphorus (BP). On the other hand, the accessible and low-cost 3D printers and design software converted the 3D printing methods into affordable fabrication tools worldwide. The implementation of this technique for the preparation of new composites based on 2D materials provides an excellent platform for next-generation technologies. This review focuses on the recent advances of 3D printing of the 2D materials family and its applications; the newly created printed materials demonstrated significant advances in sensors, biomedical, and electrical applications.

Printability Study of a Conductive Polyaniline/Acrylic Formulation for 3D Printing

There is need for developing novel conductive polymers for Digital Light Processing (DLP) 3D printing. In this work, photorheology, in combination with Jacobs working curves, efficaciously predict the printability of polyaniline (PANI)/acrylate formulations with different contents of PANI and photoinitiator. The adjustment of the layer thickness according to cure depth values (C_d) allows printing of most formulations, except those with the highest gel point times determined by photorheology. In the working conditions, the maximum amount of PANI embedded within the resin was ≃3 wt% with a conductivity of 10^-5 S cm^-1, three orders of magnitude higher than the pure resin. Higher PANI loadings hinder printing quality without improving electrical conductivity. The optimal photoinitiator concentration was found between 6 and 7 wt%. The mechanical properties of the acrylic matrix are maintained in the composites, confirming the viability of these simple, low-cost, conductive composites for applications in flexible electronic devices.

Additive Manufacturing of Conducting Polymers: Recent Advances, Challenges, and Opportunities

Conducting polymers (CPs) have been attracting great attention in the development of (bio)electronic devices. Most of the current devices are rigid two-dimensional systems and possess uncontrollable geometries and architectures that lead to poor mechanical properties presenting ion/electronic diffusion limitations. The goal of the article is to provide an overview about the additive manufacturing (AM) of conducting polymers, which is of paramount importance for the design of future wearable three-dimensional (3D) (bio)electronic devices. Among different 3D printing AM techniques, inkjet, extrusion, electrohydrodynamic, and light-based printing have been mainly used. This review article collects examples of 3D printing of conducting polymers such as poly(3,4-ethylene-dioxythiophene), polypyrrole, and polyaniline. It also shows examples of AM of these polymers combined with other polymers and/or conducting fillers such as carbon nanotubes, graphene, and silver nanowires. Afterward, the foremost applications of CPs processed by 3D printing techniques in the biomedical and energy fields, that is, wearable electronics, sensors, soft robotics for human motion, or health monitoring devices, among others, will be discussed.

Assessment of Naturally Sourced Mineral Clays for the 3D Printing of Biopolymer-Based Nanocomposite Inks

The present study investigated the possibility of obtaining 3D printed composite constructs using biomaterial-based nanocomposite inks. The biopolymeric matrix consisted of methacrylated gelatin (GelMA). Several types of nanoclay were added as the inorganic component. Our aim was to investigate the influence of clay type on the rheological behavior of ink formulations and to determine the morphological and structural properties of the resulting crosslinked hydrogel-based nanomaterials. Moreover, through the inclusion of nanoclays, our goal was to improve the printability and shape fidelity of nanocomposite scaffolds. The viscosity of all ink formulations was greater in the presence of inorganic nanoparticles as shear thinning occurred with increased shear rate. Hydrogel nanocomposites presented predominantly elastic rather than viscous behavior as the materials were crosslinked which led to improved mechanical properties. The inclusion of nanoclays in the biopolymeric matrix limited hydrogel swelling due the physical barrier effect but also because of the supplementary crosslinks induced by the clay layers. The distribution of inorganic filler within the GelMA-based hydrogels led to higher porosities as a consequence of their interaction with the biopolymeric ink. The present study could be useful for the development of soft nanomaterials foreseen for the additive manufacturing of customized implants for tissue engineering.

Highly Flexible and Photo-Activating Acryl-Polyurethane for 3D Steric Architectures

An acryl-functionalized polyurethane (PU) series was successfully synthesized using poly(tetramethylene ether) glycol-methylene diphenyl diisocyanate (PTMG-MDI) oligomer based on urethane methacrylates to control the flexibility of photo-cured 3D printing architectures. The mass ratio of acryl-urethane prepolymer: 1,4-butanediol (BD) chain-extender: diphenyl(2,4,6-trimethylbenzoyl) phosphine oxide (TPO) photoinitiator was 10:0.25:1. To produce suitably hard and precisely curved 3D architectures, the optimal UV absorbance and exposure energy of the acryl-PTMG-MDI resin were controlled precisely. Owing to the optimized viscosity of the acryl-PTMG-MDI resins, they could be printed readily by digital light processing (DLP) to form precisely curved 3D architectures after mixing with 1,6-hexanediol diacrylate (HDDA). The acryl-PTMG-MDI formulations showed much better flexural resolution than the neat resins. The printed 3D structure exhibited high surface hardness, good mechanical strength, and high elasticity for flexible applications in consumer/industrial and biomedical fields.

Influence of Graphene Oxide Contents on Mechanical Behavior of Polyurethane Composites Fabricated with Different Diisocyanates

The exceptional behavior of graphene has not yet been entirely implicit in the polymer matrix. To explore this fact in the present work, two series of Polyurethan (PU) composites were synthesized. The structural modification was observed by the use of two different diisocyanate of methylene diisocyanate (MDI) and hexamethylene diisocyanate (HMDI) in hydroxylterminated polybutadiene (HTPB) by using I,4 Butane diol (BD) as the chain extender. The variation in hard segment up to 25 (wt.%) in both series led to significant changes in the mechanical behavior of graphene oxide (GO) induced composites. Both series were prepared by an in situ polymerization process. Fourier transform infrared (FTIR) analysis showed a peak in the region of 1700 cm⁻¹, which confirmed the conversion of the NCO group into urethane linkages. Thermal gravimetric analysis (TGA) revealed a thermal stability up to 450 °C @ 90% weight loss. The swelling behavior showed the optimum uptake of 30% of water and 40% of dimethyl sulfoxide (DMSO) with aliphatic diisocyanate. The values of storage modulus (E′), complex modulus (E*), and compliance complex (D*) were observed up to 7 MPa, 8 Mpa, and 0.7 MPa⁻¹, respectively. The degree of entanglement (N) values were calculated from DMA and were found in the range of 1.7 × 10⁻⁴ (mol/m³). Phase segregation of PU was observed by scanning electron microscopy (SEM), elucidating the morphology of composites.

Synthesis and Characteristics of Eco-Friendly 3D Printing Material Based on Waterborne Polyurethane

Photo-cured 3D architectures are successfully printed using the designed waterborne polyurethane-acrylate (WPUA) formulation. A WPUA series is synthesized in the presence of polycaprolactone diol (PCL) and 4,4′-methylene dicyclohexyl diisocyanate (H₁₂MDI) as the soft segment part, dimethylolbutanoic acid (DMBA) as the emulsifier, and triethylamine (TEA) as the neutralizer, as a function of prepolymer molecular weight. The compatibility of WPUA and the photo-activating acryl monomer is as a key factor to guarantee the high resolution of 3D digital light processing (DLP) printing. The optimized blending formulations are tuned by using triacrylate monomers instead of diacrylate derivatives. For the high-accuracy and fine features of 3D DLP printing, WPUA are designed to be a suitable molecular structure for a 385 nm wavelength source, and the target viscosity is achieved in the range from 150 to 250 Cp. Photo-cured 3D architectures based on WPUA exhibit good flexural strength and high resolution.

Design and Development of a Fully Printed Accelerometer with a Carbon Paste-Based Strain Gauge

In this paper, we present a fully printed accelerometer with a piezoresistive carbon paste-based strain gauge printed on its surface, which can be manufactured at low cost and with high efficiency. This accelerometer is composed of two parts: a sensor substrate made from high-temperature resin, which is printed by a 3D printer based on stereolithography apparatus (SLA), and a carbon paste-based strain gauge fabricated by screen-printing technology and by direct ink writing (DIW) technology for the purposes of comparison and optimization. First, the structural design, theoretical analysis, simulation analysis of the accelerometer, and analyses of the conductive mechanism and the piezoresistive mechanism of the carbon paste-based strain gauge were carried out. Then the proposed accelerometer was fabricated by a combination of different printing technologies and the curing conditions of the carbon paste were investigated. After that, the accelerometers with the screen-printed strain gauge and DIW strain gauge were characterized. The results show that the printing precision of the screen-printing process on the sensor substrate is higher than the DIW process, and both accelerometers can perform acceleration measurement. Also, this kind of accelerometer can be used in the field of measuring body motion. All these findings prove that 3D printing technology is a significant method for sensor fabrication and verification.

Fabrication of Poly(vinyl alcohol)-Polyaniline Nanofiber/Graphene Hydrogel for High-Performance Coin Cell Supercapacitor

Electroactive polymer hydrogel offers several advantages for electrical devices, including straightforward synthesis, high conductivity, excellent redox behavior, structural robustness, and outstanding mechanical properties. Here, we report an efficient strategy for generating polyvinyl alcohol–polyaniline–multilayer graphene hydrogels (PVA–PANI–MLG HDGs) with excellent scalability and significantly improved mechanical, electrical, and electrochemical properties; the hydrogels were then utilized in coin cell supercapacitors. Production can proceed through the simple formation of boronate (–O–B–O–) bonds between PANI and PVA chains; strong intermolecular interactions between MLG, PANI, and PVA chains contribute to stronger and more rigid HDGs. We identified the optimal amount of PVA (5 wt.%) that produces a nanofiber-like PVA–PANI HDG with better charge transport properties than PANI HDGs produced by earlier approaches. The PVA–PANI–MLG HDG demonstrated superior tensile strength (8.10 MPa) and higher specific capacitance (498.9 F/cm², 166.3 F/cm³, and 304.0 F/g) than PVA–PANI HDGs without MLG. The remarkable reliability of the PVA–PANI–MLG HDG was demonstrated by 92.6% retention after 3000 cycles of galvanostatic charge–discharge. The advantages of this HDG mean that a coin cell supercapacitor assembled using it is a promising energy storage device for mobile and miniaturized electronics.