3D Printing of Short-Carbon-Fiber-Reinforced Thermoset Polymer Composites via Frontal Polymerization

3D printing of fiber-reinforced thermoset composites is desirable for rapid fabrication of 3D composite objects with minimal tooling. One of the main issues in 3D printing of thermoset composites is the low cure rates of matrix resins, which prevents rapid curing and rigidization of composite materials during the printing process and capturing the desired print geometry. Here, we demonstrate a new technique for in situ printing and curing of carbon-fiber-reinforced thermoset composites without any postcuring or postprocessing steps. Upon extrusion and deposition of the composite ink from a printing nozzle, the ink is cured via frontal polymerization, leading to rapid printing of high-quality composites. Tailoring the processing conditions allows for freeform or rapid, supported printing of 3D composite objects with zero void content and highly oriented carbon fiber reinforcements.