Shelf-Stable Bingham Plastic Polyurethane Thermosets for Additive Manufacturing

Abstract

Here, this study presents an innovative 3D-printing method for fabricating hybrid-hardness polyurethane (PU) thermosets via direct-ink writing (DIW). This method features an unprecedentedly long pot-life of at least 16 months for uncured material, achieved by employing internally-blocked polymeric uredines as the isocyanate source. This innovation not only extends pot life but also broadens the pre-print processing temperature range. Surface-modified fumed silica, used as a rheology modifier, ensures the maintenance of Bingham fluid characteristics. Rigorous evaluations, including DSC, tensile tests, SEM, OM, and μ-CT, verify the material’s uniform and nearly isotropic structure, devoid of defects. DMA analysis reveals that these 3D-printed PUs withstand processing temperatures up to 240°C. The practical application of this technology is demonstrated through the successful 3D printing of a shoe sole, showcasing the ability to incorporate regions of varying hardness, highlighting the versatile property customization of this method.