Photocurable High-Energy Polymer-Based Materials for 3D Printing

Area of Science:

• Materials Science
• Additive Manufacturing
• Polymer Chemistry

Background:

• Digital Light Processing (DLP) is a promising additive manufacturing technique for high-energy materials due to its non-thermal nature.
• Existing methods often involve high temperatures, which can be detrimental to the stability of high-energy materials.
• UV-cured photopolymers offer a potential solution for 3D printing energetic materials.

Purpose of the Study:

• To investigate the feasibility of using a UV-cured urethane methacrylate polymer for DLP 3D printing of high-energy materials.
• To characterize the polymerization behavior, mechanical properties, and thermal performance of the developed photocurable resin.
• To evaluate the potential of this approach for fabricating complex, high-energy systems.

Main Methods:

• Formulation of a UV-cured urethane methacrylate polymer containing 70 wt.% ammonium salt-based high-energy solid powder.
• Study of the polymerization kinetics and curing depth as a function of UV light power density.
• Mechanical testing (compressive and tensile strength) and thermogravimetric analysis (TGA) of the 3D printed samples.
• Measurement of burning rate under varying pressure conditions.

Main Results:

• Increased UV radiation transparency of the powder enhanced curing depth, ranging from 600 µm to 2 mm.
• DLP 3D printed parts achieved 92% of full density with compressive strength of 29 ± 3 MPa and tensile strength of 13 ± 1.3 MPa.
• Thermogravimetric analysis indicated a decrease in decomposition temperature for the composite resin, accompanied by significant heat generation.
• Burning rate increased from 0.74 to 3.68 mm/s with pressure increase from 0.1 to 4 MPa.

Conclusions:

• DLP 3D printing using the proposed UV photocurable resin is a viable method for fabricating high-energy materials.
• The technique allows for the production of complex-profile parts with controlled energetic properties.
• Further research can optimize the formulation for enhanced performance and safety in energetic systems.