Nanostructure-reinforced epoxy-acrylate interpenetrated networks for UV-curable high-performance coatings

High-performance coatings require rapid and sustainable processing, robust mechanical properties, and long-term durability. However, conventional epoxy systems rely on slow and energy-intensive thermal curing. Here, we develop UV-curable epoxy-acrylate systems optimized through three sequential stages: neat UV-cured epoxy, interpenetrating epoxy-acrylate networks, and nanoclay-reinforced IPN composites. The formulations cure into ~300 μm films under 2 min of UV exposure, removing the need for thermal treatment. The epoxy-acrylate networks exhibit a markedly increased hardness (up to 38% increase) and improved water-barrier performance compared to neat UV-cured epoxy. The incorporation of nanoclay platelets yields nanostructure-reinforced epoxy-acrylate composite coating and further enhances materials' thermal stability, reduces water uptake (by up to 46%), and improves stiffness (by up to 50%). Mechanical property predictions from finite-element analysis (FEA), derived from experimentally measured hardness and modulus values, confirmed the formation of efficiently reinforced and mechanically stable networks across the optimized compositions. Moisture transport was quantified using Fickian sorption models, establishing clear correlations between polymer network architecture, platelet alignment, and material stiffness with water barrier behavior. Together, these results demonstrate a predictable and tunable route to rapidly and sustainably produce high-performance UV-curable epoxy-acrylate coatings for marine environment applications, combining the speed of photopolymerization with the durability of nanoparticle-reinforced thermoset composites. • Three-stage route to high-performance nanoclay-reinforced interpenetrated networks. • Optimal UV exposure enabled complete curing of 300 μm films within >2 min. • IPN/nanoclay composite coatings reduce water uptake by 46%. • Developed IPN/nanoclay coatings show up to 38% higher hardness.