DOE OSTI · 2584139
Frontal polymerization of thermosets to enable vacuum-formed structural electronics
Abstract
Material design and accessible manufacturing are often at odds with each other, calling for creative solutions to adapt high-performance materials to available processes. This challenge is represented well by in-mold electronics, an innovative approach to the manufacture of 3D circuitry and electronic components that offers game-changing advantages. In-mold electronics relies on vacuum forming processes, which are historically limited to thermoplastics. Extending these methods to include thermosets would enable manufacturing of robust components with desirable properties. Here, we provide a solution to make thermoset materials amenable to vacuum forming. Specifically, an ambient polymerization is used to transition a liquid monomeric solution to an elastomeric gel. These free-standing gels can then be vacuum formed, and the reaction can be completed via frontal polymerization. Thermoset materials produced with this method have properties that provide benefits over traditionally employed thermoplastic substrates and enable 3D device integration into environmentally demanding architectural, automotive, and extraterrestrial structures.
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Fowler, Hayden Elise [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Taylor, Mychal Spring [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Nguyen, Chi Phuong Huu [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Boese, David Arthur [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Baca, Esteban Michael [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Greenlee, Andrew James [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Kaufman, Georgia Elizabeth [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Gallegos, Michael Alfonso [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)], Huntley, Emily F. [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)] (ORCID:000900006470040X), Appelhans, Leah N. [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)] (ORCID:0000000221359173), Kaehr, Bryan James [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)] (ORCID:0000000292277060), Leguizamon, Samuel Carlos [Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)] (ORCID:0000000333956562). 2025-05-05. Frontal polymerization of thermosets to enable vacuum-formed structural electronics. https://doi.org/10.1038/s41467-025-59455-1
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