Foaming, dual-curing, and additive manufacturing method and additive manufactured resin elastomer obtained therefrom

A method of manufacturing a foaming dual-curing resin composition through additive manufacturing comprising the following operations:

• a resin providing process, comprising:
• providing the foaming dual-curing resin composition suitable for additive manufacturing, the foaming dual-curing resin composition comprising a matrix resin and heat-expandable microcapsules;
• an additive manufacturing process, comprising:
• placing the foaming dual-curing resin composition in a printer of continuous liquid interface production, and subjecting the foaming dual-curing resin composition to ultraviolet (UV) irradiation, thereby undergoing a photopolymerization reaction to form a substantial part, which defines a plurality of mesh structures, wherein
• the plurality of mesh structures collectively form a three-dimensional network structure that constitutes an intermediate object;
• and
• heat-expandable microcapsules mixed within the foaming dual-curing resin composition are embedded in the substantial part of the plurality of mesh structures of the intermediate object during the photopolymerization reaction;
• and
• a foaming process comprising:
• removing the intermediate object manufactured from the continuous liquid interface production from the printer and placing the intermediate object in a thermal environment so that the heat-expandable microcapsules embedded in the substantial part are heated and expand, enlarging the three-dimensional network structure of the intermediate object, and the intermediate object is thermally cured in the thermal environment and forms an additive manufactured resin elastomer.