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Yet, higher solid loadings of resins and the resulting dramatic increases in viscosity limit DLP printing for applications that depend upon maximization of filler content. In this work, we investigate the capacity of a bimodal particle size distribution to enable the printing of a photosensitive resin containing up to 70 vol% of fillers. Formulations with unimodal and bimodal solid loadings ranging from 50 to 72 vol% are prepared and their viscoelastic properties measured through rotational rheometry. The zero-shear viscosity of these formulations is fit with a Krieger-Dougherty model, and the dense random close packing fraction of particles determined from the fit is found to be 76.3 vol%. Parts with fine positive and negative features are printed to evaluate the resolution achievable with highly filled photosensitive resins. The part printed with a 70 vol% formulation shows negative features as small as 860\u2009\u03bcm, and positive feature as small as 380\u2009\u03bcm. Finally, parts with complex patterns are prepared with previously tested formulations, and thermogravimetric analysis results show that the filler content within the parts remains relatively constant over a 3-h print, with a decrease of 2 vol% of solids for the final printed layers.<\/jats:p>","DOI":"10.1089\/3dp.2022.0305","type":"journal-article","created":{"date-parts":[[2023,10,10]],"date-time":"2023-10-10T10:55:39Z","timestamp":1696935339000},"page":"1819-1828","source":"Crossref","is-referenced-by-count":6,"title":["Increasing Printable Solid Loading in Digital Light Processing Using a Bimodal Particle Size Distribution"],"prefix":"10.1177","volume":"11","author":[{"ORCID":"https:\/\/orcid.org\/0000-0001-6261-6423","authenticated-orcid":false,"given":"Antoine P.","family":"Delarue","sequence":"first","affiliation":[{"name":"Department of Mechanical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA."}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Ian M.","family":"McAninch","sequence":"additional","affiliation":[{"name":"Army Research Directorate, US Army Combat Capabilities Development Command-Army Research Laboratory, Aberdeen Proving Ground, Maryland, USA."}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Amy M.","family":"Peterson","sequence":"additional","affiliation":[{"name":"Department of Plastics Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA."}],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Christopher J.","family":"Hansen","sequence":"additional","affiliation":[{"name":"Department of Mechanical Engineering, University of Massachusetts Lowell, Lowell, Massachusetts, USA."}],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"179","published-online":{"date-parts":[[2024,10,22]]},"reference":[{"key":"e_1_3_6_2_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.mtcomm.2018.12.017"},{"key":"e_1_3_6_3_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.compscitech.2019.05.003"},{"key":"e_1_3_6_4_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.addma.2018.06.009"},{"key":"e_1_3_6_5_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.applthermaleng.2020.115015"},{"key":"e_1_3_6_6_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.powtec.2019.09.066"},{"key":"e_1_3_6_7_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.msea.2019.138768"},{"key":"e_1_3_6_8_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.ceramint.2019.02.195"},{"key":"e_1_3_6_9_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matlet.2012.01.019"},{"key":"e_1_3_6_10_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.ceramint.2019.09.242"},{"key":"e_1_3_6_11_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.addma.2020.101353"},{"key":"e_1_3_6_12_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.mtphys.2022.100675"},{"key":"e_1_3_6_13_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jmmm.2017.04.066"},{"key":"e_1_3_6_14_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matdes.2021.110172"},{"key":"e_1_3_6_15_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.compositesa.2021.106532"},{"key":"e_1_3_6_16_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.addma.2019.100883"},{"key":"e_1_3_6_17_2","doi-asserted-by":"publisher","DOI":"10.1002\/adma.201401804"},{"key":"e_1_3_6_18_2","doi-asserted-by":"publisher","DOI":"10.1073\/pnas.1715157115"},{"key":"e_1_3_6_19_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.ceramint.2019.09.219"},{"key":"e_1_3_6_20_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jeurceramsoc.2021.12.016"},{"key":"e_1_3_6_21_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.compscitech.2021.109185"},{"key":"e_1_3_6_22_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.jiec.2020.12.011"},{"key":"e_1_3_6_23_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.addma.2020.101716"},{"key":"e_1_3_6_24_2","doi-asserted-by":"publisher","DOI":"10.1021\/acsapm.8b00165"},{"key":"e_1_3_6_25_2","doi-asserted-by":"publisher","DOI":"10.1016\/j.matdes.2019.107960"},{"issue":"2","key":"e_1_3_6_26_2","first-page":"231","article-title":"Powder characteristics on the rheological performance of resin-based zirconia suspension for stereolithography","volume":"35","author":"Li XB","year":"2020","unstructured":"Li XB, , Zhong H, , Zhang JX, et al. 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