Highly functional bio-based methacrylate and acrylate resins were synthesized from epoxidized sucrose soyate (ESS) and incorporated into formulations for stereolithographic (SLA) printing. These formulations were compared to a commercial SLA resin and with formulations where the bioderived resins were replaced with commercial urethane acrylates. The tensile, flexural, rheological, and thermomechanical performances of the respective formulations and their prints were compared. All of the formulations were able to be printed satisfactorily with a Peopoly Moai SLA 3D printer. The acrylated ESS resin showed the highest viscosity while the methacrylated ESS resins had lower viscosities than the control urethane acrylates. The prints made from the formulations containing the methacrylated ESS resins had similar T g s to that of the urethane acrylate control formulations while the prints from the acrylated ESS resin had a lower T g . The tensile and flexural properties were consistent with the T g values in terms of modulus, but some of the prints showed surface cracking that compromised the strength properties. This study demonstrated the ability of a bio-derived material to be functionally modified and incorporated into an SLA formulation and printed in different orientations.

Stereolithography (SLA) is a widely utilized rapid additive manufacturing process for prototypes and proof-of-concept models with high resolution. In order to create structurally sound components using SLA, reinforcement needs to be incorporated in the UV-based resins typically used. However, the introduction of reinforcement into vat-based SLA printers has had limited success due to a host of processing challenges including the creation of a homogeneous resin mixture and UV-inhibiting constituents. The effectiveness of using a dual curing system, consisting of a photo and thermal initiator, for the additive manufacturing of carbon fiber short-fiber composites via vat photopolymerization, was investigated. The necessary processing parameters were developed that resulted in successful printing and curing of composites at a 5% fiber volume. Manufacturing with reinforcements that have different densities from the resin creates separation issues, either suspending to the top or settling to the bottom. Following the approaches discussed in this chapter, an even distribution of short fibers was achieved throughout SLA printed samples using a modified commercial printer. Separation was overcome by inducing a continuous flow of reinforced liquid resin in the printer vat during printing. This flow field adaptation allows commercial SLA printers the ability to produce composite parts with different densities of the constituents utilized.