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<p>This research introduces a Hybrid Vat Photopolymerization (H-VPP) system designed to fabricate functionally graded materials (FGMs) equipped with an extrusion-based resin mixing coupled with digital light projection (DLP). The system combines twin screw extrusion system along with in-situ mixing, recoating and scraping mechanism for precise resin blending, distribution and removal of uncured resin. Microscopic investigation revealed a smooth and seamless material transition from soft to hard phases with no signs of defects and delamination in all the specimens. Tensile and bending specimens with discrete and continuous gradients were fabricated to investigate the mechanical performance and the interface strength. Among all the samples, the continuous gradient specimens exhibited exceptional mechanical characteristics and structural consistency compared to discrete gradients. The findings highlight the potential of the developed H-VPP system for additively manufacturing high performance advanced polymer composites with smooth gradient transitions along with tailored mechanical properties.</p>

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Additive manufacturing of functionally graded materials using a hybrid vat photopolymerization process

  • 期刊论文

  • 发表日期：

    2025年12月4日

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  • Mayur Jiyalal Prajapati,
  • Hong-You Chen,
  • Wojciech Macek,
  • Libor Beránek,
  • Marziar Ramezani,
  • Cho-Pei Jiang

摘要

This research introduces a Hybrid Vat Photopolymerization (H-VPP) system designed to fabricate functionally graded materials (FGMs) equipped with an extrusion-based resin mixing coupled with digital light projection (DLP). The system combines twin screw extrusion system along with in-situ mixing, recoating and scraping mechanism for precise resin blending, distribution and removal of uncured resin. Microscopic investigation revealed a smooth and seamless material transition from soft to hard phases with no signs of defects and delamination in all the specimens. Tensile and bending specimens with discrete and continuous gradients were fabricated to investigate the mechanical performance and the interface strength. Among all the samples, the continuous gradient specimens exhibited exceptional mechanical characteristics and structural consistency compared to discrete gradients. The findings highlight the potential of the developed H-VPP system for additively manufacturing high performance advanced polymer composites with smooth gradient transitions along with tailored mechanical properties.