Development of 3D Printable Functional Components Using TiO2–Reinforced Photocurable Acrylate Resin Nanocomposites

Abstract The main objective of this study is to develop titania-reinforced photocurable acrylate nanocomposites for high-performance Digital Light Processing (DLP)-based additive manufacturing applications. UV-curable Nippon 114 BS and Nippon 104 YW thermosetting acrylate resins were incorporated with TiO2 nanoparticles at loadings of 0.1, 0.3, and 0.6 wt % to investigate the influence of nanotitania on curing, rheological behavior, mechanical performance, and chemical stability. Fourier Transform Infrared (FTIR) spectroscopy revealed reduced transmittance of acrylate functional groups with increasing TiO2 concentration, indicating enhanced cross-linking within the photocured network. Field emission scanning electron microscopy coupled with EDS elemental mapping confirmed the uniform distribution of TiO2 nanoparticles within the printed matrix, while thermogravimetric analysis revealed a slight enhancement in the thermal stability of the TiO2 filled nanocomposites. Rheological analysis demonstrated increased viscosity and shear-thinning behavior with filler incorporation while maintaining adequate flow characteristics for precise layer-by-layer printing. TiO2 addition significantly accelerated photopolymerization, reducing curing times from 38 to 27 and 13 to 6 s for Nippon 114 BS and from 66 to 29 and 25 to 4 s for Nippon 104 YW as filler loading increased from 0.1 to 0.6 wt %. Additionally, both 0.6 wt % nanocomposites exhibited gel contents exceeding 99%, confirming efficient network formation. Furthermore, the nanocomposites showed enhanced tensile strength and hardness along with excellent chemical resistance in acidic and alkaline environments, demonstrating their potential for advanced functional DLP-printed components.