Nigerian-born STEM researcher and additive manufacturing expert Okunzuwa Austine Ekuase has developed a pioneering technique that significantly enhances the mechanical and thermal performance of 3D-printed nanocomposites produced through Digital Light Processing (DLP) printing. His innovative approach addresses one of the most persistent challenges in photopolymer-based 3D printing—weak mechanical integrity due to incomplete curing.
Ekuase, whose academic portfolio includes degrees from the University of Ilorin (Nigeria), Lancaster University (UK), and Southern University and A&M College (USA), focused his Master’s research on improving material performance in advanced manufacturing. His thesis, titled “Thermo-Mechanical Characterization of CNT and Basalt Hybrid Reinforced Photopolymer Composite via 3D DLP Printing,” explores a hybrid nanofiller system capable of solving the UV-shielding problem commonly encountered when using carbon nanotubes (CNTs).
“DLP 3D printing excels at producing high-resolution, cost-effective parts, but its mechanical limitations remain a barrier for functional applications,” Ekuase explained. “Improving the degree of cure is essential for fully unlocking its potential.”
CNTs are well known for their exceptional mechanical and thermal properties, making them attractive reinforcement candidates. However, their strong UV-absorption characteristics often lead to incomplete resin curing, reduced cross-linking, and lower part strength.
To overcome this limitation, Ekuase introduced basalt nanofibers (BNFs)—a cost-effective, mechanically robust, and translucent filler that allows deeper UV penetration during curing. His research investigated both mono-filler systems (CNT-only, BNF-only) and hybrid CNT–BNF combinations across varying weight fractions.
Ekuase’s findings showed that basalt nanofiber (BNF)–reinforced samples cured more effectively than those containing carbon nanotubes (CNTs), due to better UV-light transmission. By combining both fillers, he achieved performance levels far superior to either material alone. An optimal hybrid ratio of 15% CNT to 85% BNF at low loading produced higher tensile strength, improved modulus, and over 30% greater toughness. This hybrid design minimized porosity, enhanced cross-linking, and delivered stronger, better-cured 3D-printed composites.
A New Path Forward for Functional 3D-Printed Components
This hybrid technique offers a practical and scalable strategy for strengthening photopolymer-based printed parts, paving the way for their use in aerospace components, optical applications, energy devices, and other high-performance engineering systems.
“This innovation has the potential to reshape how nanocomposites are formulated for DLP printing,” Ekuase said. “My goal is to continue advancing additive manufacturing technologies that support stronger, smarter, and more functional materials.”
Beyond additive manufacturing, Ekuase has also designed a conceptual tidal stream turbine for renewable energy applications, optimized using finite element analysis and prototyped for validation in Lancaster University’s wave tank facility.
With more than eight years of industrial experience in advanced manufacturing and production engineering, Ekuase continues to contribute to global STEM advancement and inspire the next generation of innovators.
