Build materials for printing 3D articles

1. A polymerizable liquid comprising:

an acrylate component;

a composite resin comprising a curable carrier and polymeric particles dispersed in the curable carrier; and

a photoinitiator component; wherein the acrylate component comprises a mixture of acrylate monomer and acrylate oligomer and the acrylate monomer is present in an amount of 40-95 wt. % based on total weight of the acrylate component.

2. The polymerizable liquid of claim 1 , wherein the acrylate component is present in an amount up to about 80 wt. % based on total weight of the polymerizable liquid.

3. The polymerizable liquid of claim 1 ,

wherein the acrylate component is present in an amount of 30-70 wt. % based on total weight of the polymerizable liquid.

4. The polymerizable liquid of claim 1 , wherein the polymeric particles of the composite resin comprise elastomer.

5. The polymerizable liquid of claim 1 , wherein the polymeric particles exhibit a core-shell architecture.

6. The polymerizable liquid of claim 5 , wherein the polymeric particles comprise an elastomeric core.

7. The polymerizable liquid of claim 6 , wherein the polymeric particles comprise a thermoplastic shell.

8. The polymerizable liquid of claim 6 , wherein the polymeric particles comprise a thermoset shell.

9. The polymerizable liquid of claim 1 , wherein the polymeric particles are present in an amount of 20-60 wt. % based on total weight of the composite resin.

10. The polymerizable liquid of claim 1 , wherein the polymeric particles have an average size less than 1 μm.

11. The polymerizable liquid of claim 1 , wherein the polymeric particles have an average size of 50 nm to 500 nm.

12. A polymerizable liquid comprising:

an acrylate component;

a composite resin comprising a curable carrier and polymeric particles dispersed in the curable carrier; and

a photoinitiator component; wherein the curable carrier is polymerizable via free radical polymerization.

13. The polymerizable liquid of claim 12 , wherein the curable carrier comprises unsaturated polyester, vinyl ester, or mixtures thereof.

14. The polymerizable liquid of claim 12 , wherein the curable carrier is copolymerizable with the acrylate component.

15. The polymerizable liquid of claim 1 , wherein the curable carrier is not copolymerizable with the acrylate component.

16. The polymerizable liquid of claim 1 , wherein the composite resin is present in an amount of 20-70 wt %, based on total weight of the polymerizable liquid.

17. A method of printing a three-dimensional article comprising:

providing the polymerizable liquid of claim 5 ,

irradiating the polymerizable liquid with light to form the article, the article comprising a polymeric composite material including a polymeric matrix comprising an acrylate phase and a cured carrier phase, wherein the polymeric particles are disposed in the polymeric matrix.

18. The method of claim 17 , wherein:

the polymerizable liquid is provided in a layer-by-layer process;

the acrylate component is present in the polymerizable liquid in an amount of 20-80 wt. % based on total weight of the polymerizable liquid;

the composite resin is present in the polymerizable liquid in an amount of 20-70 wt. % based on total weight of the polymerizable liquid;

the polymeric particles of the composite resin comprise elastomer;

the polymeric particles are present in the composite resin in an amount of 20-60 wt. % based on total weight of the composite resin;

the polymeric particles have an average size less than 1 μm;

the curable carrier comprises unsaturated polyester, vinyl ester, or mixtures thereof; and

the acrylate component and curable carrier are copolymerized to form the polymeric matrix.