Development and Characterization of Reactive Extrusion Additive Manufacturing System and Polymer

Abstract

Additive manufacturing with polymers can rapidly produce complex geometry and prototypes but does not usually utilize thermoset polymers aside from photocurable polymers. In this study two-part reactive thermoset resin systems were used to additively manufacture parts utilizing a commercial resin and a custom resin system. Two displacement syringe drivers were used to feed each part of the reactive resin into a mix chamber that utilized a helical static mix rod and was extruded through a 3D printed nozzle. After print parameters were fine-tuned, the resulting reactive resin specimens featured high strength, quick curing, and fast deposition rate. Optimization of the resin system is required to allow for support structures to be created as well as for overhangs and other additive manufacturing advantages to be realized. Continued study on reactive extrusion methods can lead to the utilization of continuous fiber to allow for the creation of complex geometry high performance composites.