Impact of Nanoparticle Size and Loading on Printability of Composite Inks for Direct Ink Writing

Abstract Direct ink writing (DIW) using polymer‐particle composite inks is a new research area enabling a wide range of new functionalities. Despite extensive studies, there remains a need for a deeper understanding of how particle size and loading specifically influence printability, especially in the nano range. This work aims to systematically evaluate the effects of SiO₂ nanoparticle size (26–847 nm) and loading on printability within a polydimethylsiloxane (PDMS) matrix. For the single‐layer printing process, which is influenced by the substrate properties, a 3D printing line analysis (3D‐PLA) is developed to monitor the top and side views of printed lines. It is found that line width varies with ink composition and substrate, while the line height decreases with solvent evaporation, indicating a strong confinement effect from the substrate. For multilayer structures, dual‐layer printing analysis (DLPA) is utilized to evaluate the printability. It is shown that DLPA is independent of the substrate and can be used to compare the printabilities from different inks. Both 3D‐PLA and DLPA can be correlated to the rheological behavior of the ink through ink rheology analysis (IRA). Finally, this research defined the design space for DIW by benchmarking the minimum and maximum particle loadings for printable composite inks.