Rapid, Energy-Efficient CFRP manufacturing via filament winding of frontal polymerization resins

Radical-Induced Cationic Frontal Polymerization (RICFP) was successfully adapted for rapid and energy-efficient curing of carbon fiber-reinforced composites using industrial filament winding. Two aerospace-grade epoxy systems based on BADGE and BFDGE were formulated following a broad screening of reactive diluents. To meet manufacturing requirements, the curing process was modified into a thermally supported frontal polymerization (TSFP) approach, wherein a self-sustaining curing front is triggered locally and maintained via continuous external heat input to compensate for thermal losses. Using this method, composites with fiber volume fractions exceeding 58% were cured in significantly less time and with reduced energy consumption compared to standard industrial oven processes. Mechanical characterization showed increased interlaminar shear strength, lower outgassing, and comparable axial tensile properties relative to a reference BADGE system. Other properties (transverse tensile, torsion, compression, and glass transition) were lower but may be improved through further resin optimization. Finally, process scalability and performance were demonstrated through the manufacture and testing of a composite overwrapped pressure vessel, which withstood internal pressures of up to 400 bar.