New 3D-Printable Polymer Rivals Rubber in Strength

Researchers at EPFL’s Soft Materials Laboratory in Switzerland developed double network granular elastomers (DNGEs), a new class of rubber-like material with unexpectedly high strength and fatigue resistance. These materials began as a project to create better inks for 3D printing flexible devices, but testing revealed a unique ability to withstand both fractures and repeated strain, a combination rarely seen in elastomers.

The DNGEs achieve this through a dual-network structure. Rigid elastomer particles are embedded in a softer elastomer matrix, allowing stress to be shared and damage to be distributed.

This prevents localized failures and significantly increases durability. Testing showed DNGEs have fracture toughness up to 15 times greater than similar elastomers and threefold improvements in fatigue resistance. The team is now focused on making the materials more sustainable by using biodegradable and recycled elastomers, aiming to make the technology accessible to more researchers.