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Epoxy-based powder coatings are an attractive alternative to solvent-borne coatings. Here, in-house synthesized low glass transition temperature (T g ) particles containing epoxy resin and polymethyl methacrylate formed coatings at room temperature upon impact with a surface. Suspension polymerization was used to prepare particles as a function of diglycidyl ether of bisphenol A (DGEBA) and methyl methacrylate ratios. Higher incorporation of DGEBA decreased the T g to below ~20°C and eliminated the need to heat the particles and/or aluminum substrates to form coatings. Using an electrostatic powder coating apparatus, a ~70% particle deposition efficiency was achieved on aluminum substrates heated to 200°C. Whereas, at room temperature, high-speed single particle impact experiments proved that particle bonding occurred at a critical velocity of 438 m/s, comparable to commercial cold spray technologies. The in-house synthesized particles used in this study hold potential in traditional and emerging additive manufacturing applications.

Polymer Particles with a Low Glass Transition Temperature Containing Thermoset Resin Enable Powder Coatings at Room Temperature