Extrudable Thermosets Based on Dynamic Covalent Polymers

Dynamic covalent polymers (DCPs) have attracted considerable attention for fabricating self-healing, recyclable, adaptive, and malleable thermosets. However, their processing has largely depended on compression molding, which requires extended time due to the crosslinked nature of these materials. This limitation poses significant challenges for applications in continuous processes like extrusion, a technique highly valued in industry for producing long, uninterrupted products. Recently, continuous processing methods for DCPs have emerged, offering the potential to streamline their production by providing scalability and consistency-factors that could transform sectors such as automotive, aerospace, and consumer goods. Yet, developing extrudable DCPs remains a complex task, demanding the precise design of dynamic crosslinks with rapid kinetics, high thermal stability, and cost-effectiveness, all while ensuring compatibility with suitable molecular backbones. In this review, we summarize the key requirements for designing extrudable DCPs and discuss recent advancements in continuous processing techniques aligned with various design strategies. We also highlight the challenges and outline future directions for optimizing high-performance DCP extrusion, aiming to offer a valuable resource for researchers and industry professionals looking to leverage these techniques.