Frontal Polymerization: A Novel, Fast, and Energy-efficient Approach for the Manufacturing of Thermoset Polymers and Composites

Philippe Geubelle (Aerospace Engineering, University of Illinois at Urbana-Champaign)

Traditional manufacturing techniques of thermoset-matrix fiber-reinforced composites rely primarily on the bulk polymerization of the resin. In addition to the substantial capital investments associated with the need for autoclaves, ovens, or heated molds, the long and complex heat and pressure cycles involved in the thermal curing process result in a time-consuming and energy-intensive manufacturing process. Frontal Polymerization (FP), which involves a polymerization wave that propagates through a monomer converting it to polymer, has been demonstrated over the past few years by the Autonomous Materials Systems research group at the University of Illinois (Robertson et al., Nature, 2018) as an alternative approach to eliminate the need for autoclaves and make the process substantially (by orders of magnitude) faster and more energy efficient.

In this talk, I will discuss experimental and computational results on FP-based manufacturing of thermoset polymers and composites based on three different processes: Vacuum-Assisted Resing Transfer Molding (VARTM), 3D printing, and growth printing. The presentation will also cover current research activities in the deployment of FP-based manufacturing in low-earth orbit.