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<p>This study presents the formulation, rheological optimization, and mechanical characterization of UV-curable resin composites reinforced with 40&#xa0;wt.% silicon carbide (SiC) and 2&#xa0;wt.% fumed silica, designed for additive manufacturing of abrasive tools. Various additives—including fumed silica, BYK-9076, hydrophobically modified hydroxyethyl cellulose (HM-HEC), and APTES—were evaluated for their effects on suspension stability, viscosity, and 3D printability. Fumed silica at 2&#xa0;wt.% effectively reduced SiC sedimentation from 90% to below 20% within 24 h, while maintaining a printable viscosity (~&#xa0;560&#xa0;mPa&#xa0;s), aided by oil coating of SiC particles. In contrast, BYK-9076 showed dispersion under static conditions but failed under mechanical agitation. Mechanical testing of printed specimens revealed a 10.8% increase in tensile strength (48.67&#xa0;MPa versus 43.92&#xa0;MPa for pure resin), a 65% improvement in wear resistance (wear volume: 0.0016&#xa0;cm<sup>3</sup> versus 0.036&#xa0;cm<sup>3</sup>), and an increase in shore D hardness from 73.2 to 81.3, confirming enhanced surface durability. Compression testing demonstrated a 64% improvement in mean compressive strength for the composite (4.55&#xa0;MPa versus 2.77&#xa0;MPa for pure resin, ASTM D6641), further supporting its suitability for demanding abrasive applications. Printed parts using the optimized formulation exhibited improved structural integrity and adhesion, as validated through surface microscopy and mechanical tests. These results demonstrate that combining thixotropic and surface-modifying agents enables stable, printable ceramic-filled composites with significantly improved mechanical, compressive, and tribological performance, ideally suited for 3D-printed abrasive tools and other wear-resistant applications.</p>

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Formulation and Printability of SiC-Reinforced UV-Curable Resins for Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2025年9月19日

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  • Babak Houshmand,
  • Seyed Mohsen Safavi,
  • Ali Mogharehabed

摘要

This study presents the formulation, rheological optimization, and mechanical characterization of UV-curable resin composites reinforced with 40 wt.% silicon carbide (SiC) and 2 wt.% fumed silica, designed for additive manufacturing of abrasive tools. Various additives—including fumed silica, BYK-9076, hydrophobically modified hydroxyethyl cellulose (HM-HEC), and APTES—were evaluated for their effects on suspension stability, viscosity, and 3D printability. Fumed silica at 2 wt.% effectively reduced SiC sedimentation from 90% to below 20% within 24 h, while maintaining a printable viscosity (~ 560 mPa s), aided by oil coating of SiC particles. In contrast, BYK-9076 showed dispersion under static conditions but failed under mechanical agitation. Mechanical testing of printed specimens revealed a 10.8% increase in tensile strength (48.67 MPa versus 43.92 MPa for pure resin), a 65% improvement in wear resistance (wear volume: 0.0016 cm3 versus 0.036 cm3), and an increase in shore D hardness from 73.2 to 81.3, confirming enhanced surface durability. Compression testing demonstrated a 64% improvement in mean compressive strength for the composite (4.55 MPa versus 2.77 MPa for pure resin, ASTM D6641), further supporting its suitability for demanding abrasive applications. Printed parts using the optimized formulation exhibited improved structural integrity and adhesion, as validated through surface microscopy and mechanical tests. These results demonstrate that combining thixotropic and surface-modifying agents enables stable, printable ceramic-filled composites with significantly improved mechanical, compressive, and tribological performance, ideally suited for 3D-printed abrasive tools and other wear-resistant applications.