Lignin nanoparticle-enhanced biobased resins for digital light processing 3D printing: Towards high resolution and tunable mechanical properties

Abstract

The more widespread applicability of photopolymerization-based three-dimensional (3D) printing is limited by the availability of light-curable resins, most of which are based on fossil-derived compounds. We developed a biobased lignin-derivable resin by utilizing methacrylated derivatives of vanillin, vanillyl alcohol, and eugenol as aromatic monomers. Lignin nanoparticles (LNPs) were incorporated as functional fillers that enhance print resolution and material properties. The crosslinking degree, and thereby the tensile properties, was modulated through the use of mono- or dimethacrylated vanillin derivatives in the resin formulation. The LNPs acted as UV absorbers, conferring better control of the photopolymerization process by preventing light penetration across unintended layers, leading to enhanced print resolution. The LNPs showed excellent dispersion stability due to their size and morphology. The inclusion of up to 2 wt% of LNPs improved the ductility of the 3D printed nanocomposites through toughening mechanisms enabled by the rigid nanoparticles. Finally, exploiting the differences in crosslinking degree of the resin formulations, a multi-material model featuring both soft and rigid domains was fabricated. This study demonstrates a simple but effective strategy for the design of biobased photocurable resins with tailorable mechanical properties that are suitable for high-resolution and multi-material 3D printing.