Fabrication and analysis of Fe3O4/ZnO/epoxy composites via stereolithography: Structural and photocatalytic properties

Abstract

Additive manufacturing (AM) creates three-dimensional (3D) objects by adding material layer by layer, enabling faster prototyping, reduced waste, and complex geometries compared to traditional methods. Among AM technologies, stereolithography (SLA) stands out for producing precise, smooth structures by curing ultraviolet-sensitive (UV-sensitive) thermoset resin. SLA is widely used in fields like medicine, dentistry, and jewelry, especially when enhanced with nano- or microparticles for composite materials. Zinc Oxide (ZnO) is valued for its photocatalytic ability to oxidize organic pollutants under UV light, making it useful in photovoltaic panels, coatings, and textiles. Magnetite (Fe3O4), with its size-dependent magnetic properties, is widely applied in biomedical and environmental technologies. This study aimed to combine the unique features of Fe3O4 and ZnO nanoparticles in hybrid composites. Nanoparticles were added to a photosensitive resin and printed using SLA. The resulting materials were analyzed using X-ray diffraction, scanning electron microscopy, thermogravimetric analysis, Fourier transform infrared spectroscopy, vibration sample magnetometer, and UV spectrometry. Findings revealed that increasing ZnO content improved photocatalytic performance, with 7.5% ZnO achieving the highest efficiency. However, higher ZnO concentrations slightly reduced magnetic properties. The study highlights the potential of SLA-printed hybrid composites for multifunctional applications. Highlights: Fe3O4 and ZnO nanoparticles were added to resin at 2.5%, 5%, and 7.5% by weight. ZnO addition improved photocatalytic efficiency, with 7.5% reaching 73.24%. Increased ZnO in hybrid composites led to a slight decrease in magnetization.