Advanced Photocurable Acrylates and Thermoset Materials for Stereolithography: Cure-Dependent Viscoelasticity, Process–Property Relationships, and Post-Processing Effects

Abstract

Background: The rapid expansion of stereolithography (SLA) and related vat photopolymerization techniques has placed increasing emphasis on understanding the links between resin formulation, processing parameters, post-processing, and the resulting mechanical and thermal properties of printed parts. This work synthesizes extant experimental findings and theoretical frameworks regarding acrylate-based photocurable systems, thermoset behavior under varying cure states, and the role of post-rinsing and post-curing in defining final performance. The aim is to present a cohesive, publication-ready examination of how resin chemistry and processing interplay to shape viscoelasticity, diffusional phenomena, mechanical strength, and the stability of printed components. (Schittecatte et al., 2023; Müller-Pabel et al., 2022).

Methods: The article integrates critical experimental observations and mechanistic interpretations from studies on resin formulation, printing orientation, post-processing solvents, and cure kinetics. Drawing on empirical data from stereolithography resin evaluations and established rheological and diffusion theory, this synthesis constructs a composite methodological narrative that links dynamic mechanical measurements, flexural testing, roughness and cytotoxicity assessments, and thermal analysis to interpret cure-dependent viscoelasticity and process-driven heterogeneity (Salmoria et al., 2009; Keßler et al., 2021; Lambart et al., 2022).

Results: Analysis shows that resin composition and printing parameters fundamentally alter crosslink density distributions, creating spatial heterogeneities that manifest as anisotropic mechanical response and cure-dependent viscoelastic relaxation. Post-rinsing solvent choice and post-curing regimen significantly affect surface topology, residual monomer content, and bulk mechanical properties; alternative rinsing solutions yield measurable differences in roughness and flexural strength (Lambart et al., 2022; Mendes-Felipe et al., 2018). Fully biobased photoactive acrylates and novel thermoset formulations provide routes to increased thermal stability while presenting challenges in cure control and diffusion-limited conversion (Miao et al., 2020; Park et al., n.d.).

Conclusions: Optimal part performance requires harmonizing resin chemistry, printing strategy, and post-processing. A rigorous emphasis on cure mapping, viscoelastic characterization across the cure window, and solvent-resin interaction studies is urged. The article concludes with a forward-looking research agenda emphasizing multiscale characterization, predictive curing models, and targeted post-processing protocols to reduce variability and improve functional reliability in SLA-printed components (Schittecatte et al., 2023; Müller-Pabel et al., 2022).