| NSF Org: |
CMMI Division of Civil, Mechanical, and Manufacturing Innovation |
| Recipient: |
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| Initial Amendment Date: | August 5, 2019 |
| Latest Amendment Date: | December 19, 2021 |
| Award Number: | 1934120 |
| Award Instrument: | Standard Grant |
| Program Manager: |
Linkan Bian
lbian@nsf.gov (703)292-8136 CMMI Division of Civil, Mechanical, and Manufacturing Innovation ENG Directorate for Engineering |
| Start Date: | October 1, 2019 |
| End Date: | September 30, 2024 (Estimated) |
| Total Intended Award Amount: | $402,352.00 |
| Total Awarded Amount to Date: | $559,093.00 |
| Funds Obligated to Date: |
FY 2020 = $140,741.00 FY 2022 = $16,000.00 |
| History of Investigator: |
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| Recipient Sponsored Research Office: |
3124 TAMU COLLEGE STATION TX US 77843-3124 (979)862-6777 |
| Sponsor Congressional District: |
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| Primary Place of Performance: |
101Bizzell Street College Station TX US 77843-3131 |
| Primary Place of
Performance Congressional District: |
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| Unique Entity Identifier (UEI): |
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| Parent UEI: |
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| NSF Program(s): |
AM-Advanced Manufacturing, GOALI-Grnt Opp Acad Lia wIndus, Special Initiatives |
| Primary Program Source: |
01001920DB NSF RESEARCH & RELATED ACTIVIT 01002021DB NSF RESEARCH & RELATED ACTIVIT |
| Program Reference Code(s): |
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| Program Element Code(s): |
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| Award Agency Code: | 4900 |
| Fund Agency Code: | 4900 |
| Assistance Listing Number(s): | 47.041 |
ABSTRACT
This award supports a collaborative research project on a novel 3D printing method for thermosetting polymers, localized frontal curing-assisted 3D printing. Thermosetting polymers are widely used in aircraft, space shuttles, cars, boats, bridges, furniture, and so on. Currently available methods to manufacture thermosetting polymer parts include conventional molding and newly-developed mold-free 3D printing. These methods involve two steps: deposition processing and post-processing curing that are both energy-intensive and time-consuming. In localized frontal curing-assisted 3D printing, deposition and curing are completed simultaneously in a one-step process. An external heat source is used to initialize the curing process and the heat produced by the exothermic curing reaction enables curing to self-propagate through the material as it is deposited. The new method has the potential to impact product design, assembly, and the manufacture of products using thermosetting polymers. As a result it could potentially lead to significant changes and increased competitiveness in many industries of national interest, such as the automotive, aerospace, and marine industries. This project will engage graduate and undergraduate students in the research activities thus preparing them for the advanced manufacturing workforce. Outreach activities based on the research will be used at high school summer camps and for online videos to educate students and the general public about advanced manufacturing.
There are four research objectives: (1) to determine effects of curing agent concentration and printing slice size on frontal velocity and front propagation distance; (2) to understand relationships between localized frontal velocity, viscoelastic behavior of thermosetting resins, and geometric fidelity of printed structures; (3) to test the hypothesis that a specific range of frontal velocity will result in higher interlayer bonding strength; and (4) to reveal effects of localized frontal velocity on the mechanical performance of printed structures. To achieve these objectives, the research team will employ both theoretical and experimental approaches. Specifically, effects of curing agent structures and concentration on frontal curing velocity and front propagation distance will be modelled and simulated based on the reaction kinetics and then verified by high-resolution infrared camera. Viscoelastic behavior of thermosetting resins will be studied via real-time rheology characterization and data fitting. Effects of frontal velocity on interlayer bonding strength and mechanical performance of printed structures will be revealed by experimental tests and statistical analysis.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.
PUBLICATIONS PRODUCED AS A RESULT OF THIS RESEARCH
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PROJECT OUTCOMES REPORT
Disclaimer
This Project Outcomes Report for the General Public is displayed verbatim as submitted by the Principal Investigator (PI) for this award. Any opinions, findings, and conclusions or recommendations expressed in this Report are those of the PI and do not necessarily reflect the views of the National Science Foundation; NSF has not approved or endorsed its content.
Frontal curing-assisted printing of thermoset polymers offers a novel approach to 3D printing by harnessing the self-propagating nature of frontal polymerization to cure epoxy thermosets in a controlled manner, with epoxy being the most widely used material in industrial applications. The effect of the curing agent concentration and printing slice size on the frontal velocity and frontal propagation distance were disclosed through both theoretical and experiment work.Experiment-integrated modeling further revealed the effect of frontal velocity on the viscoelastic behavior of various epoxy thermosetting polymers(inlcuding sustaiable bio-derive epoxy thermosets) and geometric fidelity of the printed structures, and thus lay down a solid foundation in determining the process windows. New knowledge was also generated regarding the effect of frontal velocity on the printed interlayer bonding strength, and overall mechanical performance, offering insight in understanding the effect of frontal velocity on the mechanical properties of printing structures.This technique enables the precise fabrication of complex geometries with improved material properties, such as enhanced mechanical strength and thermal stability. The process also allows for rapid and efficient polymerization, offering potential advances in both the speed and scalability of thermoset printing. This technology has the potential to revolutionize manufacturing, particularly in industries requiring durable, heat-resistant materials such as aerospace, automotive, and medical devices. By improving the efficiency and accessibility of 3D printing for thermosets, it can reduce waste and energy consumption compared to traditional methods. Additionally, it could foster innovation in areas like custom prosthetics, lightweight structures, and advanced materials, providing broader economic and societal benefits by enabling new, high-performance applications and enhancing the sustainability of manufacturing practices.
Last Modified: 01/05/2025
Modified by: Shiren Wang
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