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Frontal polymerization (FP) is an approach for thermosetting plastics atlower energy cost than an autoclave. The potential to generate simultaneouspropagation of multiple polymerization fronts has been discussed as an excitingpossibility. However, FP initiated at more than two points simultaneously hasnot been demonstrated. Multi-point initiation could enable both large scalematerial fabrication and unique pattern generation. Here the authors presentlaser-patterned photothermal heating as a method for simultaneous initiation ofFP at multiple locations in a 2-D sample. Carbon black particles are mixed intoliquid resin (dicyclopentadiene) to enhance absorption of light from aTi:Sapphire laser (800 nm) focused on a sample. The laser is time-shared byrapid steering among initiation points, generating polymerization using up toseven simultaneous points of initiation. This process results in the formationof both symmetric and asymmetric seam patterns resulting from the collision offronts. The authors also present and validate a theoretical framework forpredicting the seam patterns formed by front collisions. This framework allowsthe design of novel patterns via an inverse solution for determining theinitiation points required to form a desired pattern. Future applications ofthis approach could enable rapid, energy-efficient manufacturing of novelcomposite-like patterned materials.

Polymer patterning by laser-induced multi-point initiation of frontal polymerization