Multifaceted Mechanics of Novel Printable Bioresin for Skeletal Implants

ABSTRACT Advancing personalized orthopedic medicine requires a fundamental understanding of the relationships among formulation, processing, and the mechanical response of additively manufactured biomaterials. This study investigates six generations of vat‐photopolymerized acrylic formulations based on a crosslinked poly(methyl methacrylate‐ co ‐ethylene glycol dimethacrylate) network modified with linear poly(methyl methacrylate) and containing hydroxyapatite, silver oxide, and copper nanoparticles, selected for their potential osteogenic and antibacterial functions. Quasi‐static tensile testing with full‐field digital image correlation characterizes elastic modulus, ultimate tensile strength, strain‐to‐failure, and Poisson's ratio. Dynamic mechanical analysis evaluates the temperature‐dependent storage and loss moduli, damping, and glass transition temperature. The formulations exhibit elastic moduli near 3 GPa and Poisson's ratios of 0.36–0.40, with composition‐dependent tensile and thermomechanical responses. The fully hybridized formulation exhibits a storage modulus of approximately 2.6 GPa at 41°C and a glass transition temperature of approximately 107°C. Optical fractography identifies brittle, edge‐initiated failure, as well as formulation‐ and processing‐related heterogeneities. Diamond and gyroid triply periodic minimal surface structures demonstrate the feasibility of fabricating architected geometries from the particle‐containing resin. These results establish a mechanical and thermomechanical basis for further evaluation of the formulations in orthopedic implant applications.