Frontal polymerization for UV‐ and thermally initiated EPON 826 resin

Frontal polymerization has great potential in complementing additive manufacturing processes such as direct ink writing as a continuous cure synchronized to the printing speed can overcome issues such as sagging. To study the incorporation of frontal polymerization into a potential printing process, a frontally polymerizable DGEBA epoxy resin has been developed for both UV and thermal initiation. Through frontal polymerization alone, full conversion is observed with a starting glass transition of 150°C for both initiation methods. Resulting thermal behavior is shown to have little dependence on either initiation irradiance or temperature utilized and much greater dependence on initiator concentration in the resin. Mechanical behavior is maximized by varying initiator concentration and cure conditions achieving tensile stress of 75 MPa and K1C of 1.2 MPa‐m1/2. Shelf stability of the resin proves promising with no viscosity change after 12 weeks of room temperature storage. Future studies will concern adapting the resin for both direct ink writing and continuous fiber additive manufacturing applications.Highlights Frontal polymerization of EPON 826 using RICFP Utilized a tetrakis borate containing diaryliodonium cationic initiator Stable and polymerizable after 12 weeks Resin printed and frontally cured using UV initiation