Vat photopolymerization of silica reinforced styrene-butadiene rubber elastomeric nanocomposites

Compared to their unfilled counterparts, elastomeric nanocomposites offer tailorable combinations of properties, including improved mechanical properties, increased durability, and enhanced thermal and electrical conductivity. However, the high viscosity caused by the presence of both the high molecular weight elastomer and the inclusion of fillers complicates additive manufacturing (AM) of elastomeric nanocomposites. This is especially challenging in vat photopolymerization (VP) AM, which requires resins that possess low viscosity (< 10 Pa·s) and exhibit sufficient storage modulus (∼ 10 Pa) when photocured. To address this process limitation, the authors have previously demonstrated decoupling the relationship between viscosity and molecular weight via VP of a photocurable composite latex resin. In this approach, a photocurable matrix is photocured as a scaffold around the latex particles, which provides sufficient modulus for the printed "green" part. Following a dehydration post-processing step, the latex particles coalesce to provide the final elastomeric mechanical properties without compromising feature resolution.