Optimizing polymer composite dielectric properties via digital light processing 3D printing of ordered barium titanate skeleton

Through construction of a three-dimensional continuous ceramic network, the dielectric performance of polymer composites can be enhanced with a reduced amount of ceramic loading. However, the commonly employed methods, such as freeze casting or sacrificial template, fail to precisely control the structure of the ceramic skeleton, leading to significant randomness in content control. In this work, a Digital Light Processing (DLP) 3D printing technique is utilized to precisely fabricate ordered three-dimensional ceramic structures, which are further sintered at high temperatures to obtain a continuous barium titanate (BT) skeleton (BTS). This is then compounded with cyanate ester based polymers (CP) to prepare BTS/CP composites. Results show that when the content of BT is 61.2 vol%, the dielectric constant of the composite is 657 at 100 Hz, which is about 173 times higher than CP, while maintaining a lower dielectric loss of 0.026. Interestingly, the distribution of BTS in the composites has a significant impact on the dielectric performance of the composite. When the BT content is about 50 vol%, the dielectric constant of the “fine and dense” skeleton composite is 2.1 times higher than that of the “coarse and sparse” skeleton composite. This study proposes a novel strategy for building a structurally and compositionally controllable three-dimensional barium titanate (BT) network within polymers, demonstrating the noteworthy influence of macrostructure on the dielectric performance of polymer composites. This offers a fresh approach to the mass application of ordered three-dimensional ceramic skeleton enhanced polymer composites in the fields of electronics and electricity. Digital light processing 3D printing of ordered barium titanate skeleton for precisely customizing high dielectric constant ceramic/polymer composites. [Display omitted] •Preparing structurally controllable barium titanate skeleton using DLP 3D printing.•Preparing "3-3" type dielectric polymer composites with ordered ceramic structure.•The prepared composites have high dielectric constant and low dielectric loss.