Frontal Polymerization of Epoxy Resins: Kinetic Modeling, Rate Regulation and Curing Process Simulation for Space Manufacturing Applications

Frontal polymerization (FP) technology has attracted significant attention as an efficient, low-energy curing method for thermosetting resins. By enabling self-sustaining polymerization reactions, FP significantly reduces curing time and minimizes external energy dependence, making it ideal for in-orbit manufacturing applications. In contrast to traditional curing methods, which are limited by high energy consumption and low efficiency, FP offers a more efficient and flexible alternative. Nonetheless, the FP process is sensitive to material composition, processing and environmental factors, requiring systematic studies to enhance performance. This work focuses on reaction mechanisms, curing kinetics and processing factors of a self-developed FP epoxy resin system. The revealed curing mechanism and kinetics reveals a high initiation energy barrier and rapid curing characteristics, showing appropriate reaction inertness before initiation and stable reaction without continuous external energy input. The influences of initiator concentration and epoxy resin type on polymerization rate and the properties of cured resin were examined. Additionally, a curing simulation method validated by the experiment were employed to analyze the effects of mold material, resin cross-sectional area, initial temperature and environmental conditions on polymerization behavior. The results provide valuable insights for optimizing FP, advancing the understanding of the curing process and improving resin performance in space-based applications.