Researchers develop new carbon nanotube-based nanocomposites, optimized particularly for vat photopolymerization sort 3D printing
SEOUL, Sept. 26, 2025 /PRNewswire/ — Polymer-based conductive nanocomposites, notably these incorporating carbon nanotubes, are extremely promising for the event of versatile electronics, gentle robotics and wearable gadgets. However, CNTs are troublesome to work with as they have an inclination to agglomerate, making it arduous to acquire a uniform dispersion. Moreover, standard strategies restrict management over CNT distribution and form.
The proposed carbon nanotube-based nanocomposites facilitate 3D printing of extremely stretchable and delicate piezoresistive sensors that can be utilized to develop excessive efficiency, wearable well being monitoring gadgets.
To overcome these challenges, researchers are turning to additive manufacturing (AM) or 3D printing strategies, resembling vat photopolymerization (VPP), which supply wonderful design freedom with excessive printing accuracy. In this methodology, a lightweight is used to selectively treatment and harden layers of an ink inside a vat, steadily constructing a 3D object. Despite its benefits, it additionally poses a number of challenges. The presence of CNTs impacts the printability and curing properties of the inks. Moreover, concurrently attaining excessive stretchability and electrical conductivity is a significant problem.
Now, a analysis crew led by Professor Keun Park and Associate Professor Soonjae Pyo from the Department of Mechanical System Design Engineering at Seoul National University of Science and Technology in Korea has efficiently fabricated extremely stretchable, electrically conductive CNT-nanocomposites, utilizing VPP-type 3D printing. “Our new CNT-nanocomposites are optimized specifically for VPP-based processes, allowing fabrication of highly complex 3D structures,” explains Prof. Park. “We also used these materials to additively manufacture new piezoresistive sensors and integrated them into a wearable health monitoring device.” Their research was made obtainable on-line on August 25, 2025 and revealed within the Volume 372 of the journal Composite Structures on November 15, 2025.
The crew first ready polymer nanocomposite inks by uniformly dispersing multi-walled carbon nanotubes (MWCNTs) into an aliphatic urethane diacrylate (AUD) resin, with concentrations starting from 0.1 to 0.9 weight%. To obtain uniform dispersion, they agitated the combination utilizing ultrasonic waves. The ready inks had been then analyzed to find out the optimum printing situations.
Next, the crew additively manufactured take a look at specimens utilizing the assorted inks and examined them for their mechanical and electrical properties, in addition to printing decision (the minimal thickness that may be printed). Results confirmed that the formulation with 0.9 weight% CNT provided one of the best steadiness of properties. It might stretch as much as 223% of its unique size earlier than breaking, whereas nonetheless attaining a exceptional electrical conductivity of 1.64 ×10−3 S/m, surpassing that of beforehand reported supplies. It additionally achieved a printing decision of 0.6 mm.
To show sensible applicability, the researchers used the optimized CNT nanocomposite to 3D print versatile triply periodic minimal floor (TPMS)-based piezoresistive sensors that confirmed excessive sensitivity and dependable efficiency. Importantly, they built-in these sensors into an insole to create a smart-insole platform. Using this platform, the crew might monitor the stress distribution on the backside of the foot in actual time, detecting totally different human actions and postures.
“The developed smart-insole device demonstrates the potential of our CNT nanocomposites for 3D printing the next generation of highly stretchable and conductive materials,” remarks Prof. Pyo, “We believe these materials will be indispensable for wearable health monitors, flexible electronics and smart textiles.“
Reference
Title of unique paper: Photopolymerization additive manufacturing of extremely stretchable CNT nanocomposites for 3D-architectured sensor functions
Journal: Composite Structures
DOI: 10.1016/j.compstruct.2025.119614
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