Achieving high-performance multi-material resins for 3D printing in biomedical applications demands careful formulation strategies that enable the integration of components with desirable properties. The integration of ceramic nanoparticles into polymer matrices allows the development of systems that combine the flexibility of polymers with the strength and functionality of ceramics. This approach is particularly advantageous due to ceramics’ superior mechanical strength, structural stability, and biocompatibility. However, to fully realize these benefits, uniform dispersion of ceramic particles is essential. Proper control of nanoparticle distribution prevents agglomeration and improves printability, mechanical performance, and structural integrity, which are critical attributes for applications such as tissue engineering and bone scaffolds. In this study, a new photosensitive resin formulation based on PEGDA–SOEA with TiO₂ nanoparticles was developed to meet these challenges. This innovative multi-material resin was designed for vat photopolymerization to enhance both printability and mechanical properties for biomedical use. A specific ultrasonic mixing procedure was used to overcome challenges related to nanoparticle sedimentation and agglomeration, ensuring homogeneous dispersion within the polymer matrix. Furthermore, resin viscosity and curing behavior were optimized to ensure consistent layer formation and structural integrity, enhancing mechanical properties and printability. SEM/EDX analysis confirmed a relatively uniform dispersion of TiO₂ nanoparticles at concentrations of 0.5, 1.0, and 1.5 wt%. SEM images showed well-defined structures supporting uniform crosslinking throughout the cured samples. These advancements highlight a new resin formulation with improved structural consistency, enhanced mechanical performance, and superior printability, opening new possibilities for its application in advanced biomedical fields.
