All services are investing in additive manufacturing of metals, polymer-based materials and composites due to the attractive opportunities in prototyping, parts reduction and complexity. However, current off-the-shelf materials do not exhibit the properties necessary for demanding defense applications, in which durability, thermo-oxidative stability and low creep under extreme conditions (high temperature, humidity, oxygen) are key requirements. This presentation will discuss several routes that enable the use of state-of-the-art chemistries known from conventional polymer matrix composites to be used in additive manufacturing processes, including selective laser sintering and fused deposition modeling. The newly designed resin systems allow 3D printing of parts with service temperatures well above 300C and excellent thermo-oxidative stability. Synthesis, formulation, feedstock development and 3D printing of these new materials and their thermo-mechanical properties will be presented.

Old thermoset chemistries for a new process. High temperature thermosetting resins for additive manufacturing

256th National Meeting (2018)

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