FPP3D: Coupling frontal photopolymerisation and interfacial wrinkling for single shot 3D patterning

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The solidification of polymeric materials by light exposure is a common approach in coatings and patterning technologies. Under specific conditions, a solidification front (defined by the interface between liquid and solid) is sharp and, driven by light, travels thereby invading the unpolymerised material. Such light-driven travelling wave polymerisation processes give rise to frontal photopolymerisation which is an attractive manufacturing tool for multi-level patterns and objects. It is thus desirable that the liquid-solid front is planar and smooth. However, interfacial "roughness" may occur at certain front velocities, light intensity, temperature, time and other manufacturing conditions. This project will investigate and control this "roughness" - caused by wrinkling, folding and creasing of the interface - to manufacture functional surfaces of high value. An experimental capability map and predictive computational tool will be established and validated and then applied to rapidly prototype exemplars of this novel manufacturing approach, including optically active materials with smooth 3D profiles.