(9d) Additive Manufacturing of Core-Shell Microparticles Containing Thermosetting Resins

Yang, G., University of Massachusetts Amherst
Huang, M., University of Massachusetts Amherst
Klier, J., University of Massachusetts Amherst
Schiffman, J. D., University of Massachusetts Amherst
Cold spray deposition is a common additive manufacturing method for fabricating metal coatings that involves the spraying metal particles at high-speeds. However, this scalable, additive manufacturing process has not yet generated solid polymer coatings. Our study enables the cold spraying of solid polymer materials at room temperature. Here, we developed novel, core-shell thermoplastic microparticles containing a high concentration of thermosetting resins. Suspension polymerization was employed to produce the microparticles due to its many advantages, namely low conversion cost, mature scale-up processing, and a versatile tunability in terms of particle size and morphology. The thermal properties, size distribution, morphology, and composition of the particles were explored and fine-tuned in an effort to optimize the deposition of the particles at room temperature using cold spray technology. The outcome of this study is a novel form of sprayable thermosetting powders that deposit to form a coating with a high performance, easy operation processing, significant environmental benefits, and a commercial feasibility.