Application of Mullite Nanowhisker-reinforced Polyurethane Composites in 3D Printing

Abstract This study discussed the application of mullite nanowhisker-reinforced polyurethane composites in 3D printing. The composite materials were fabricated via in-situ polymerization technique, with their thermomechanical properties, microstructural characteristics, and thermal stability systematically investigated. The 3D printing process parameters were optimized, and the performance of the printed products was evaluated. Experimental results demonstrated that the incorporation of mullite nanowhiskers induced significant enhancements in the composite materials’ mechanical properties and thermal stability. Compared with pure polyurethane, the composites’ tensile properties, bending properties, and fracture toughness were increased by 60%, 62%, and 87%, respectively. At the same time, the coefficient of thermal expansion is reduced by about 20 units. Optimized 3D printing can produce products with good dimensional accuracy and surface quality. This study proposes a novel methodology for engineering advanced 3D printing materials, demonstrating significant potential for widespread application in industrial domains, including but not limited to aerospace engineering and automotive manufacturing sectors.