The development of thermosetting polymers from readily available and affordable sources that feature high thermal and mechanical properties is crucial towards an advancement of current resins used in stereolithography (SLA) 3D printing. Bio-based isosorbide methacrylate has been previously shown to produce thermosets with glass transition temperatures (Tg) of over 200 °C, making it an excellent candidate in an SLA production of durable materials. Building upon these results, we compared isosorbide-based (meth)acrylates to their bisphenol A analogues and commercial vinyl ester resins. Due to the aliphatic core of isosorbide, the corresponding resins displayed viscosities that were 5 and 25 times lower than that of bisphenol A (meth)acrylates and vinyl esters, respectively. Furthermore, the isosorbide resins had higher extents of cure, likely due to their lack of photo-absorbing aromatic rings that are present in the other resin systems. The bio-based isosorbide resins retained their high Tg of over 200 °C, which were significantly higher than that of other tested (meth)acrylate systems, making them very attractive for SLA 3D printing applications. Additionally, we demonstrated that photo-cure times of relatively thick specimens can be shortened from as long as 25 min to less than 30 seconds using a reflective substrate and/or addition of a thermal initiator, while simultaneously enhancing the extent of cure. Lastly, we investigated the effect of partially acrylated epoxy resins on the processing, extent of cure, morphology, thermal properties, and mechanical properties of a variety of photocured and thermally postcured thermoset polymers. Although the epoxy-containing additives increased the viscosity of the resins, significant weight fractions of these components can be used while maintaining adequate Tg and viscosities that are acceptable for additive manufacturing applications.

Photopolymerizable and durable bio-based isosorbide resins for additive manufacturing

255th National Meeting (2018)

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