Cold Spray-Based Additive Manufacturing of Thermosets

Abstract

This research proposes an approach of utilizing thermosetting polymer powders for additive manufacturing via a customized low-pressure cold spray system. To reveal the underlying deposition mechanisms during the polymer powder-impacting process, the microstructure, thermal and mechanical properties of deposited samples are examined and compared with those of the as-received and fully cured materials. It is found that severe plastic deformation, partial melting, and curing reaction (including latent curing agent decomposition and cross-link reaction) occur simultaneously to form the bonding. However, due to the insufficient heat generation for complete cross-linking reaction, a post-heat treatment is needed to improve the mechanical properties of the fabricated objects, where a low heating rate is necessary to maintain the sample geometry.