Simultaneous three-dimensional printing and frontal polymerization of dicyclopentadiene resin

Three-dimensional (3D) printing has widespread uses across many industries due to its versatility and capabilities. However, freeform fabrication of thermoset polymers remains a technical challenge. This thesis combines 3D printing with frontal polymerization (FP) — a method to rapidly cure resin — for curing filaments in tandem with the printing process. A partially cured dicyclopentadiene (DCPD) resin was developed into a printing ink. Critical rheological characteristics were identified, and DCPD inks of varying incubation times were screened to find the most suitable properties. Results of the rheological study indicate that 90 minutes of incubation time resulted in optimum print behavior. Problems associated with FP were effectively tackled through temperature control across the printing setup. In situ infrared images showed an exothermic reaction front propagating during the print process, giving evidence of in situ polymerization. The optimized technique produced one-dimensional, two-dimensional and 3D freeform prints with excellent fidelity. A self-equilibrating behavior was identified in the reaction front, such that the front autonomously tune its speed to the programmed print speed. This phenomenon autonomously controls the viscoelastic bridge length, Lb, and inevitably curbs deformations to achieve high print fidelity.

Name thesis:degree_name

M.S.

Level thesis:degree_level

Thesis

Discipline thesis:degree_discipline

Aerospace Engineering

Grantor

University of Illinois at Urbana-Champaign

Year dc:date

2019

Author dc:creator

• Aw, Jia En

Contributors dc:contributor

• Sottos, Nancy R.
• Geubelle, Philippe H.

• 3D printing
• thermoset
• frontal polymerization
• direct ink writing
• advanced manufacturing

Statement dc:rights

• Copyright 2019 Jia En Aw

Language dc:language

en

Handle dc:identifier

http://hdl.handle.net/2142/105277

OAI record oai:identifier

https://www.ideals.illinois.edu/oai-pmh?verb=GetRecord&metadataPrefix=etdms&identifier=oai%3Awww.ideals.illinois.edu%3A2142%2F105277