Dual-Cure Vapor-Grown Carbon Nanofiber-Supplemented 3D-Printed Resin: Implications for Improved Stiffness and Thermal Resistance

Stereolithography (SL), often referred to as an advanced manufacturing technique, is employed to conveniently fabricate bulk and delicate objects with UV-curable resin due to its high accuracy and versatility. However, the poor performance exhibited by UV-curable resin limits the practical applicability of SL. In this study, the acidified vapor-grown carbon nanofibers (VGCFs)-supplemented dual-cure 3D-printed SL resin nanocomposites are prepared by a facile method to avoid non-homogeneous curing and improve the overall performance of the printed workpieces effectively. The dual-cure nanocomposites with 1% w/w VGCFs exhibit a tensile strength of 63.5 MPa, which is improved by 10% over pure resin, and Young’s modulus of 3.2 GPa increases up to 19% with the addition of 2% w/w VGCFs. As confirmed by nanoindentation tests, the apparent homogeneity of nanocomposites is achieved by using the dual-cure method. Moreover, these nanocomposites exhibit excellent thermal properties, revealing that they could be conveniently employed in a high-temperature environment. Notably, the thermal conductivity of the nanomaterials supplemented with 2% w/w VGCFs is increased by 79%. Together, these nanocomposites by SL with enhanced mechanical properties, thermal resistance, and thermal conductivity could open a broad range of high-end applications, such as mold manufacturing, aerospace, and electronic-based devices.