Paper Number
PO3 My Program
Session
Poster Session
Title
3D printing epoxy thermosets: Additive manufacturing of polymerization-induced phase separating materials
Presentation Date and Time
October 22, 2025 (Wednesday) 6:30
Track / Room
Poster Session / Sweeney Ballroom E+F
Authors
- C'de Baca, Francesca M. (Sandia National Laboratories, Organic Materials Science)
- Van Meter, Kylie E. (Sandia National Laboratories, Organic Materials Science)
- Jones, Brad H. (Sandia National Laboratories)
Author and Affiliation Lines
Francesca M. C'de Baca, Kylie E. Van Meter and Brad H. Jones
Organic Materials Science, Sandia National Laboratories, Albuquerque, NM 87123
Speaker / Presenter
C'de Baca, Francesca M.
Keywords
additve manufacturing; advanced manufacturing
Text of Abstract
Epoxies are widely used across various technical industries due to their exceptional physical and chemical stability, as well as their tunable thermomechanical properties. We have developed heterogenous epoxies that feature hard and soft domains with phase-separated length scales which are systemically tuned from the macroscale to nanoscale. We employ polymerization-induced phase separation (PIPS) to adjust the phase composition and scale, enabling the selection of specific thermomechanical properties and morphologies. 3D printing of these materials would allow for the creation of hierarchical structures, with tailored properties for specific applications. However, there are significant challenges in printing step-growth epoxies due to their slow reaction kinetics. In this work, we focus on the development of printable phase-separated epoxies. Direct ink write printing (DIW) was used to print formulations primarily consisting of epoxy resin and amine curing agents, with a secondary UV curable acrylate component and rheological modifiers. Rheological measurements of these formulations were used to tailor inks for printability, both through in-situ UV cure measurements and thixotropic testing. The dual-cure formulation allows for printed structures to be partially cured via UV exposure during the print, providing green strength, follow by a final thermal polymerization step resulting in phase separation of the epoxy system. This method enables the control of mesoscale structure through phase separation and macroscale structure through printing. Dynamic mechanical analysis of printed materials reveals distinct phase separation of these materials along with the high tunability of glass transition profiles and other properties. This approach not only enhances the performance of epoxy materials but also paves the way for advanced applications in additive manufacturing, ultimately contributing to the development of more efficient and versatile materials in various industries.