Researchers at The University of Texas at Dallas have created a 3D-printed foam that offers improved durability and recyclability compared to conventional polymer foams. The new material, detailed in the March 1 print edition of RSC Applied Polymers, was developed through a two-year research project led by doctoral student Rebecca Johnson. The team successfully demonstrated their concept by producing foam in the shape of a balloon dog, showcasing the ability to create complex, customized shapes.
“The goal of the project was to address some limitations in 3D printing in terms of making polymer foam,” said Dr. Ron Smaldone, associate professor of chemistry and biochemistry and the study’s corresponding author. “One of the main uses, or interests, for 3D-printable foams is insulation and shock absorption.”
Unlike traditional thermoset foams that cannot be reshaped or recycled once molded, the UT Dallas foam utilizes dynamic covalent chemistry with reversible bonds. This approach allows the material to repair itself when damaged, potentially extending its usable life. According to Smaldone, with further research, this type of foam could be used in high-impact absorption applications such as helmets, car bumpers, or armor.
The researchers faced significant challenges in making the polymer formulation compatible with 3D printing technology. However, this manufacturing method enables the creation of more complex structures like fine lattices, which can increase the material’s physical flexibility and application versatility.
Chemistry doctoral student Ariel Tolfree, who co-led the study with Johnson, plans to expand the research by examining ways to enhance the foam’s recyclability and sustainability potential. The project received funding from The Welch Foundation, the National Science Foundation, and the Department of Energy.
Source: news.utdallas.edu
