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Photopolymerization-based additive manufacturing methods like stereolithography and digital light processing only allow typically the monolithic fabrication of structures made from a single material. To overcome this limitation, grayscale digital light processing has been proposed for 3D printing of functionally graded materials. Here, this concept is extended to grayscale masked stereolithography (MSLA) printing using a LED light source and a LCD photomask to control the degree of photopolymerization of a UV-curable resin by varying grayscale pixels and thus light intensities. In this scale, tailorable hyperelastic material properties and functionally graded structures for finite deformations are realized. In this paper, the dependency of the resulting material properties on the parameters of the grayscale MSLA process is investigated and a grayscale-dependent hyperelastic material model is formulated. This parametric hyperelastic material model is fitted to the experiments and validated against experimental results for uniaxial tension and uniaxial compression tests. Then, functionally graded structures with tailored mechanical properties at finite deformations are designed and fabricated using grayscale MSLA printing. The hyperelastic material model is validated with experimental results for different geometries, showing good agreement between experimental tests and numerical calculations.

Additive manufacturing, Stereolithography, Hyperelastic materials, Functionally graded materials