Rapid multiple-front polymerization of fiber-reinforced polymer composites

Frontal polymerization (FP) is an out-of-autoclave, self-sustaining cure process that enables rapid and energy-efficient manufacturing of composites compared to conventional processes. Prior FP demonstrations for both polymer composite materials rely on one front achieve full cure. In this work, we investigate the effect multiple fronts time, quality, mechanical performance. Localized void formation, panel thickness increase, thermal spike are measured between two merging observed have a detrimental impact Numerical simulations guide mitigation by modifying layup from thermally insulated boundaries (TIB) conductive (TCB). Panels manufactured with TCB successfully mitigate all adverse phenomena at fronts, leading improved properties. A 5-fold reduction in time ca. 5 min one-front TIB panels 1 two-front achieved.