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      Understanding and Improving Mechanical Properties in 3D printed Parts Using a Dual-Cure Acrylate-Based Resin for Stereolithography

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          Abstract

          Application of 3D printed structures via stereolithography (SLA) is limited by imprecise dimensional control and inferior mechanical properties. These challenges is attributed to poor understanding ofpolymerization behavior during the printing process and inadequate post-processing methods. The former via a modified version of Jacob’s working curve equation that incorporates the resin’s sub-linear response to irradiation intensity is addressed by the authors. This new model provides a more accurate approach to select 3D printing parameters given a desired z-resolution and conversion profile along the depth of the printed part. The authors use this improved model to motivate a novel material design that can be post-processed to be indistinguishable from the polymer at 100% conversion. This approach employs a dual initiating system in which photo-initiated printing is followed by a thermal post-cure to achieve uniform conversion. The authors show that this approach enables fast printing times (10 s per layer), exceptional horizontal resolution (1–10 microns), precise control over vertical resolution, and decreased surface corrugations on a 10’s of microns scale. The techniques described herein use an acrylate-based SLA resin, but the approach can be extended to other monomer systems to simultaneously achieve predictable properties and dimensions that are critical for application of additive manufacturing in load-bearing applications.

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          Author and article information

          Contributors
          Journal
          101537646
          38353
          Adv Eng Mater
          Adv Eng Mater
          Advanced engineering materials
          1438-1656
          1527-2648
          6 January 2019
          20 September 2018
          December 2018
          01 December 2019
          : 20
          : 12
          : 1800876
          Affiliations
          Materials Science and Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Materials Science and Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Department of Mechanical Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Materials Science and Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Department of Chemical and Biological Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Materials Science and Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Department of Electrical Computer and Energy Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Materials Science and Engineering University of Colorado Boulder Boulder, CO 80309, USA
          Article
          PMC6370025 PMC6370025 6370025 nihpa1004424
          10.1002/adem.201800876
          6370025
          30766445
          9971ef1e-d194-4c33-bf3a-754b6b22d60e
          History
          Categories
          Article

          mechanical properties of 3D printed parts,post-cure,3D printing,stereolithography,Jacob’s working curve

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