Investigating Microstructural and Mechanical Behavior of DLP-Printed Nickel Microparticle Composites

The study investigates the fabrication and analysis of nickel microparticle-reinforced composites fabricated using the digital light processing (DLP) technique. A slurry is prepared by incorporating Ni-micro particles into a resin vat; it is thoroughly mixed to achieve homogeneity. Turbidity fluctuations are observed, initially peaking at 50 within the first two minutes of mixing and then stabilizing at 30 after 15–60 min. FTIR spectroscopy with varying Ni wt. is performed to study the alterations in the composite material’s molecular structure and bonding environment. Spectrophotometric analysis revealed distinctive transmittance signatures at specific wavelengths, particularly within the visible light spectrum, with a notable peak at 532 nm. The effects of printing orientation in the X, Y, and Z axes were also studied. Mechanical properties were computed using tensile strength, surface roughness, and hardness. The results indicate substantial enhancements in the tensile properties, with notable increases of 75.5 in the ultimate tensile strength and 160 in the maximum strain. Minimal alterations in surface roughness and hardness suggest favorable printability. Microscopic examination revealed characteristic fracture patterns in the particulate composite at different values for the wt. of nickel. The findings demonstrate the potential of DLP-fabricated Ni-reinforced composites for applications demanding enhanced mechanical performance while maintaining favorable printability, paving the way for further exploration in this domain. © 2024 by the authors.