Digital light processing (DLP) has the advantages of higher printing speed and product precision than other 3D printing technologies. However, DLP products have low mechanical strength owing to the inherent properties of photocurable materials. Graphitic carbon nitride (GCN), which is an abundant hydrogen bonding motif (-NH2, -NH), has low solubility in most solvents; thus, to use GCN as a reinforcement of the polymer matrix, optimal dispersion processes must be applied. In this study, GCN was proposed as a novel reinforcing material to improve the mechanical properties of photocurable epoxy acrylate (EA) resins for DLP. Herein, two-step (planetary mixing and ultrasonication) processes were applied to disperse GCN within EA, and the dispersion performance was identified by checking the degree of precipitation over time. To test the printability of the dispersed GCN/EA composites subjected to DLP 3D printing, cube specimens of GCN/EA composites were prepared, and the dispersed GCN/EA output had a low dimensional error of 0.3-1.3%, while the undispersed composite output showed larger dimensional errors of 27.7-36.2%. Additionally, in the mechanical test of the DLP-3D-printed sample (dispersed GCN/EA composite), the tensile strength and elastic modulus of the dispersed GCN/EA composite specimen were measured to be 75.56 MPa and 3396 MPa, respectively, which were improved by 22% (tensile strength) and 34% (modulus of elasticity) in relation to those of the neat EA specimen. This study is the first to use GCN as a reinforcement and manufacture a composite product for DLP with excellent performance (22% increased tensile strength) through the optimal dispersion of GCN. Considering the high mechanical performance, DLP products using the GCN/EA composites can be used in industries such as automobiles, shipbuilding, and aviation.
Keywords: digital light processing 3D printing; dispersion process; graphitic carbon nitride; polymer additive manufacturing; reinforcement.