This paper proposes an innovative approach to address the challenge of softening deformation of thermal-curable thermosets during additive manufacturing. This approach involves the development of a composite powder composed of thermosetting materials with distinct curing temperatures, the utilization of Cold Spray Additive Manufacturing (CSAM) technology for 3D printing, and the application of a stepwise isothermal curing process. The corresponding effectiveness is validated by case studies. The results demonstrate that samples printed via CSAM maintain a solid state without deformation. During the post-curing process, each component of the composite material cures independently while the other components remain in a solid state, providing structural support for the whole material, thereby effectively reducing the softening deformation during the post-curing process. This approach offers a novel perspective for the additive manufacturing of thermal-curable thermosets.

Poly(2,6-dimethyl phenyl oxide) (PPO) is known for its low dissipation factor. To achieve insulating materials with low dissipation factor for high-frequency communication application, a monomer-type benzoxazine (P-APPO) and a main-chain-type benzoxazine (BPA-APPO) were prepared from an amine end-capped oligo (2,6-dimethyl phenylene oxide) (APPO). The APPO was prepared from a nucleophilic substitution of a phenol-end capped oligo (2,6-dimethyl phenylene oxide) (a commercial product, SA 90) with fluoronitrobenzene, and followed by catalytic hydrogenation. After self-curing or curing with a dicyclopentadiene-phenol epoxy (HP 7200), thermosets with high-T_g and low-dissipation factor can be achieved. Furthermore, the resulting epoxy thermosets show better thermal and dielectric properties than those of epoxy thermoset cured from its precursor SA90, demonstrating it is a successful modification in simultaneously enhancing the thermal and dielectric properties.

The combination of eco-respectful epoxy compounds with the humins, a by-product of biomass chemical conversion technologies, allow the obtention of materials with high added value. In this work, we propose the chemical connection study of humins with two aliphatic diepoxides through the copolymerization reactions to synthesize sustainable bio-based thermosets. The mechanism insights for the crosslinking between the epoxides and humins was proposed considering the different functionalities of the humins structure. FT-IR spectroscopy, 1 D and 2 D NMR spectroscopy techniques were used to build the proposed mechanism. By these techniques, the principal chain connections and the reactivity of all the components were highlighted in the synthesized networks.