The integration of self-healing properties in photopolymer-based materials could give new impetus to the stagnating market for light-based 3D printing systems. While global sales of photopolymers for additive manufacturing have remained at around 650 million US dollars since 2021, there is growing interest in functional materials that go beyond purely mechanical properties. This class of materials promises particular advantages in safety-critical applications such as aerospace.
A research team has developed a dual resin system that combines a thermoplastic with a light-curable thermoset-based plastic. The challenge was to create an optically homogeneous mixture that remains permeable to UV light – a basic requirement for curing in the DLP or SLA printing process. During exposure, the thermoset component solidifies, while the thermoplastic phase remains meltable. In the event of damage, this can be liquefied again locally by heating so that it can flow into cracks and act as a structural bond after cooling.
The formulations tested showed an almost complete recovery of the mechanical properties after the curing process. In addition, the strength and toughness of the components improved compared to conventional photopolymers – albeit at the expense of printability. The increased viscosity and complex phase behavior of the material mixture make processing in the printing process more difficult.
The research work provides new insights into the optimization of self-healing photopolymers in the additive manufacturing process. In addition to aerospace, areas of application in biomedicine, soft robotics or function-integrated coatings are also conceivable. In an industry increasingly focused on resource efficiency and durability, such systems could play an important role in the future.
Find out more about the Rochester Institute of Technology at rit.edu.
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