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Manufacturing Thermoset Lattice Core Sandwich Panel via Frontal Polymerization.

Maxwell Condell¹, Ryan Ruiz¹, Erin Poyer¹

¹Department of Mechanical Engineering, University of Wyoming, 1000 E. University Avenue, Laramie, Wyoming 82071, United States.

ACS Applied Polymer Materials

|April 16, 2026

Summary

Frontal polymerization (FP) enables direct-ink writing of lattice core sandwich panels, eliminating bonding steps. This advanced manufacturing technique yields stronger, void-free composite structures compared to traditional methods.

Keywords:

additive manufacturing dicyclopentadiene frontal polymerization lattice core sandwich panel thermoset

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Published on: May 17, 2018

Area of Science:

Polymer Science
Materials Engineering
Additive Manufacturing

Background:

Frontal polymerization (FP) is an exothermic reaction front for rapid polymer curing.
Direct-ink writing (DIW) utilizes FP for printing polymer structures.
Existing methods for lattice core sandwich panels (LCSPs) require separate bonding steps.

Purpose of the Study:

Develop a manufacturing technique for thermoset LCSPs using FP-based DIW.
Eliminate the need for additional bonding between lattice cores and face sheets.
Investigate the properties of FP-manufactured LCSPs.

Main Methods:

FP-based DIW was employed to print lattice cores.
An IR camera monitored and controlled FP front velocity for accuracy.
Face sheets were formed by immersing lattice cores in ink and initiating FP.
Compressive tests compared FP-manufactured parts with FDM-fabricated ones.

Main Results:

FP-based DIW successfully fabricated thermoset LCSPs with integrated face sheets.
Real-time monitoring and control of FP front velocity improved printing accuracy.
Fabricated panels exhibited good dimensional accuracy and full bonding without voids.
DCPD LCSPs manufactured via FP showed significantly higher ultimate strength than FDM counterparts.

Conclusions:

FP-based DIW offers a streamlined approach for manufacturing high-performance LCSPs.
The integrated face sheet formation eliminates complex post-processing bonding.
This method presents a viable alternative for producing robust composite sandwich structures.