Evaluation of the Mechanical, Thermal, and Sustainability Performance of Cellulose Nanofibril‐Reinforced Photopolymer Composites Fabricated via Digital Light Processing

ABSTRACT

This study systematically investigates the mechanical, thermal, electrical, and environmental performance of photopolymer nanocomposites reinforced with cellulose nanofibrils (CNFs) and fabricated via Digital Light Processing (DLP). CNFs were selected due to their high aspect ratio, biodegradability, and strong interfacial bonding potential, and were incorporated into a commercial photopolymer resin at various weight fractions (0.25–2 wt%). This study differs from prior research by combining functional property evaluations with quantitative environmental impact assessment. It offers a comprehensive and sustainability‐oriented insight into the development of CNF‐reinforced photopolymer nanocomposites for high‐performance and eco‐friendly additive manufacturing applications. The results indicate that a 1 wt% CNF reinforcement yields optimal mechanical performance, achieving a 63.6% increase in ultimate tensile strength and a 26.8% increase in microhardness compared to the pristine resin. However, higher reinforcement levels lead to agglomeration, adversely affecting mechanical performance. Thermal analyses reveal delayed degradation behavior and increased residue mass with increasing CNF content, while electrical conductivity remains nearly unchanged due to the intrinsic insulating nature of CNFs. Additionally, life cycle assessment (LCA) results indicate that even at low concentrations of CNF contribute to a reduction in carbon emissions.