Polymer Manufacturing Research Articles

Nonlinear stability of two superimposed electrified dusty fluids of type Rivlin-Ericksen: Non-perturbative approach

The nonlinear instability of a planar interface between two overlapping Rivlin-Ericksen viscoelastic liquids, in the occurrence of fine dust and vertical electric fields throughout permeable media, and the influence of surface tension is studied. The prototype structure is assumed to be a two-dimensional groundwork for the sake of simplicity. The growing approval of several disciplines of practical physics and technology serves as motivation for analyzing this problem. Using viscous potential theory, the mathematical procedure is condensed. To properly control electro convection in liquid crystals, which is widely used in various displays technologies, it was crucial to have a thorough comprehension of stability. Gaining understanding of the behavior of viscoelastic fluids at interfaces was crucial in polymer manufacturing industries. Employing the linear equations of movement with the suitable nonlinear bounder circumstances forms the basis of the considered nonlinear technique. A nonlinear partial differential equation that evaluates the interface movement is the objective of the process. Since linear stability has frequently been investigated, the present situation will be constructed only in the nonlinear sense, where a number of dimensionless physical numerals are achieved. The non-perturbative methodology is used to accomplish the nonlinear standards. The main idea behind the novel performance is to convert an ordinary nonlinear ordinary differential equation into a linear one. The new technique differs from the conventional perturbation methods in that it may be used to exactly and correctly analyze the behavior of the strong nonlinear aspects of the interface displacement. This innovative method is established by using He's frequency formula. Using the nonlinear distinguishing equation, the special situation of the real and the complex coefficients is accomplished. It was observed that the instability zone expands as the electric field, porosity of porous medium, and density ratio of two fluids rise. The stability configuration is enhanced by the viscoelasticity parameter, Bond number, and ratio of kinematic viscoelasticity.

Triggering C‒N Coupling on Metal Oxide Nanocomposite for the Electrochemical Reduction of CO2 and NOx⁻ to Formamide

AbstractThe co‐electroreduction of CO2 and NOx⁻ (NO3⁻/NO2⁻) to generate formamide (HCONH2) offers an opportunity for downstream chemical and polymer manufacturing decarbonization; however, significant challenges lie in the C‒N coupling and the associated low product selectivity. Herein, p‐block metal oxides are incorporated in copper oxides to provide more accessible active sites for reactant adsorption and activation, tuning the reaction selectivity toward the formamide production. Through in situ Raman and synchrotron‐based infrared spectroscopy measurements, C─N bond formation is demonstrated in real‐time with the CuOx/BiOx catalyst, where the C─N bond is detected via a *CHO and *NH2 intermediates formation, in agreement with the density functional theory calculations. When tested in a flow electrolyzer, a formamide yield rate of 134 ± 11 mmol h−1 gcat−1 is reported, the first report of co‐electroreduction of CO2 and NOx⁻ to formamide beyond conventional H‐cell measurements. These new insights on the C‒N coupling mechanisms and scale‐up capability provide directions for further development of electrocatalysts for the formamide production.

Passion Fruit Seed Oil: A Sustainable Feedstock for Additive Manufacturing of Renewable Polymers

Passion Fruit Seed Oil: A Sustainable Feedstock for Additive Manufacturing of Renewable Polymers

ТЕХНОЛОГІЇ ОДЕРЖАННЯ ПОЛІМЕРНИХ КОМПОЗИЦІЙ ДЛЯ ВИГОТОВЛЕННЯ ПОГОНАЖНИХ ВИРОБІВ

The work is devoted to the characteristics of the technologies for obtaining a polymer composition for the manufacture of decorative products. Research is focused on the technology of manufacturing polymer composite material based on polyvinyl chloride for the production of rigid pipes, fittings, sidings, windows and doors, profiles, fences, railings, various devices, valves, housings of inspection lights, ventilation ducts, fans, heat exchange equipment, parts of chemical equipment , laboratory devices and other products. The paper describes the manufacturing technology of the PVC composition and investigates the important performance characteristics of the polymer melt. Three common technologies are presented, they are rolling, calendering and extrusion. The most common material for the manufacture of polymer. This composition is most often obtained by the extrusion method, so this section focuses on this technology in more detail resin products is a polyvinyl chloride composition. The stiffness of the polymer is characterized by the modulus of elasticity during bending. To determine this indicator, samples of polymer material without irradiation and with UV irradiation for a certain period of time were used. When the content of chalk in the recipe increases, the hardness increases. All compositions are characterized by approximately the same character - with exposure to six hours, the modulus of elasticity decreases, and with further exposure, it begins to gradually increase. The combination of а filler and a polymer is the most powerful for use in PVC compositions in the manufacture of decorative products.

Meniscal repair with additive manufacture of bioresorbable polymer: From physicochemical characterization to implantation of 3D printed poly (L-co-D, L lactide-co-trimethylene carbonate) with autologous stem cells in rabbits.

Three-dimensional (3D) structures are actually the state-of-the-art technique to create porous scaffolds for tissue engineering. Since regeneration in cartilage tissue is limited due to intrinsic cellular properties this study aims to develop and characterize three-dimensional porous scaffolds of poly (L-co-D, L lactide-co-trimethylene carbonate), PLDLA-TMC, obtained by 3D fiber deposition technique. The PLDLA-TMC terpolymer scaffolds (70:30), were obtained and characterized by scanning electron microscopy, gel permeation chromatography, differential scanning calorimetry, thermal gravimetric analysis, compression mechanical testing and study on in vitro degradation, which showed its amorphous characteristics, cylindrical geometry, and interconnected pores. The in vitro degradation study showed significant loss of mechanical properties compatible with a decrease in molar mass, accompanied by changes in morphology. The histocompatibility association of mesenchymal stem cells from rabbit's bone marrow, and PLDLA-TMC scaffolds, were evaluated in the meniscus regeneration, proving the potential of cell culture at in vivo tissue regeneration. Nine New Zealand rabbits underwent total medial meniscectomy, yielding three treatments: implantation of the seeded PLDLA-TMC scaffold, implantation of the unseeded PLDLA-TMC and negative control (defect without any implant). After 24weeks, the results revealed the presence of fibrocartilage in the animals treated with polymer. However, the regeneration obtained with the seeded PLDLA-TMC scaffolds with mesenchymal stem cells had become intimal to mature fibrocartilaginous tissue of normal meniscus both macroscopically and histologically. This study demonstrated the effectiveness of the PLDLA-TMC scaffold in meniscus regeneration and the potential of mesenchymal stem cells in tissue engineering, without the use of growth factors. It is concluded that bioresorbable polymers represent a promising alternative for tissue regeneration.

Additive Manufacturing of Composite Polymers: Thermomechanical FEA and Experimental Study.

This study presents a comprehensive approach for simulating the additive manufacturing process of semi-crystalline composite polymers using Fused Deposition Modeling (FDM). By combining thermomechanical Finite Element Analysis (FEA) with experimental validation, our main objective is to comprehend and model the complex behaviors of 50 wt.% carbon fiber-reinforced Polyphenylene Sulfide (CF PPS) during FDM printing. The simulations of the FDM process encompass various theoretical aspects, including heat transfer, orthotropic thermal properties, thermal dissipation mechanisms, polymer crystallization, anisotropic viscoelasticity, and material shrinkage. We utilize Abaqus user subroutines such as UMATHT for thermal orthotropic constitutive behavior, UEPACTIVATIONVOL for progressive activation of elements, and ORIENT for material orientation. Mechanical behavior is characterized using a Maxwell model for viscoelastic materials, incorporating a dual non-isothermal crystallization kinetics model within the UMAT subroutine. Our approach is validated by comparing nodal temperature distributions obtained from both the Abaqus built-in AM Modeler and our user subroutines, showing close agreement and demonstrating the effectiveness of our simulation methods. Experimental verification further confirms the accuracy of our simulation techniques. The mechanical analysis investigates residual stresses and distortions, with particular emphasis on the critical transverse in-plane stress component. This study offers valuable insights into accurately simulating thermomechanical behaviors in additive manufacturing of composite polymers.

A numerical study of MHD nonlinear mixed convection flow over a nonlinear vertical stretching sheet with the buoyancy and suction/injection effects

The current research has a primary focus on characterizing buoyancy-driven nonlinear mixed convection. This phenomenon is studied within the context of an MHD Newtonian flow over a vertically stretching sheet with nonlinear characteristics. Flow patterns resembling those studied in this context have practical applications in various industrial sectors. Such flow patterns have practical applications in several industrial sectors, including the article and pulp industry, polymer manufacturing, electronic device cooling, solar energy collection, gas turbine plants, and nuclear power generation. The governing partial differential equations (PDEs) for nonlinear mixed convection are transformed into higher-order nonlinear ordinary differential equations (ODEs) through appropriate transformations, and these transformed ODEs are subsequently solved numerically. The software MATHEMATICA is used to solve the boundary layer flow equations, employing the semi-analytical Galerkin weighted residual method (GWRM). This approach yielded simultaneous solutions for both cases suction and injection. For both the suction and injection situations, graphical results, such as velocity, concentration, and temperature profiles are included. An augmentation in the nonlinear stretching parameter results in a reduction in velocity near the surface of the sheet. Conversely, away from the sheet, velocity increases. Moreover, an increase in nonlinear stretching parameters corresponds to higher values for both temperature and concentration. An increase in the suction/injection parameter causes a decrease in the velocity, temperature, and concentration fields. In the scenario of assisting flow, an increase in the thermal buoyancy parameter leads to higher velocity but lower temperature. Conversely, in the case of opposing flow, an increase in the thermal buoyancy parameter results in higher values for both velocity and temperature. Furthermore, a numerical examination is conducted to analyze the values of skin friction, Sherwood number, and Nusselt number.

Design and manufacture of new hybrid hydrogel and superabsorbent polymer for controlled release of fulvic acid based on grafted xanthan gum/gelatin using electron irradiation and its use in fodder corn cultivation

A humic acid-gelatin (HA-Gel) hydrogel, a gallic acid-xanthan gum (GA-XG) hydrogel, a HA-Gel/GA-XG hydrogel, and superabsorbent polymer (SAP) of HA-Gel/GA-XG/polyacrylamide (PAM) hydrogel were synthesized using electron beam irradiation method. The capability of synthesized hydrogels in loading and controlled release of fulvic acid (FA) was studied. The chemical and physical structure of sorbents was confirmed by various analyses. The effect of irradiation dose on mechanical properties, gel percentage, swelling, and absorbency under load (AUL) of the sorbents was investigated. By changing the hydrogel structures into the SAP form, its swelling capacity was increased from 37 to 320 g/g. Both hybrid hydrogel and SAP were reusable for up to 7 cycles. The maximum fertilizer loading capacities for SAP and hybrid hydrogel were 402.1 and, 175.5 mg g−1, respectively. In comparison to hydrogels, the SAP showed a slower FA-release performance. Thus, in soil media, 86 % of FA was released in 15–20 days from the hybrid hydrogel while with the SAP, 81 % of FA was released in 30–35 days. The significant improvement in the growth of fodder corn treated with FA-loaded SAP in the greenhouse media in comparison to the control groups showed the effective performance of the designed SAP, favoring its practical applications.

Simulation of viscoelastic free-surface flows with the Particle Finite Element Method

Viscoelastic fluids are central in numerous applications from polymer manufacturing to the pharmaceutical industry and biological research. However, since analytical solutions are generally not available or too complex, it is common practice to study free-surface viscoelastic flows through numerical simulation techniques. This work proposes the use of the so-called particle finite element method (PFEM), a Lagrangian approach combining standard FEM techniques with a remeshing strategy. The PFEM is able to efficiently handle mesh distortion and to accurately track the free-surface evolution. Therefore, it is exploited in this work to deal with large displacements problems in the context of nonlinear viscoelasticity. An implementation of the Oldroyd-B constitutive model in the PFEM framework is here presented including details regarding how to deal with the transfer of the internal variables during remeshing events. Additionally, an innovative approach to impose unilateral Dirichlet boundary conditions ensuring optimal mass conservation is presented. The implementation is verified with two free-surface highly viscous benchmark flows: the impacting drop and the jet buckling problems. The results show perfect agreement with those obtained with other numerical techniques. The proposed framework opens the way for using PFEM in various applications, ranging from polymer extrusion to more sophisticated scenarios involving viscoelastic and viscoelasto-plastic constitutive laws.

High Molar Mass Polycarbonates as Closed-Loop Recyclable Thermoplastics.

Using carbon dioxide (CO2) to make recyclable thermoplastics could reduce greenhouse gas emissions associated with polymer manufacturing. CO2/cyclic epoxide ring-opening copolymerization (ROCOP) allows for >30 wt % of the polycarbonate to derive from CO2; so far, the field has largely focused on oligocarbonates. In contrast, efficient catalysts for high molar mass polycarbonates are underinvestigated, and the resulting thermoplastic structure-property relationships, processing, and recycling need to be elucidated. This work describes a new organometallic Mg(II)Co(II) catalyst that combines high productivity, low loading tolerance, and the highest polymerization control to yield polycarbonates with number average molecular weight (Mn) values from 4 to 130 kg mol-1, with narrow, monomodal distributions. It is used in the ROCOP of CO2 with bicyclic epoxides to produce a series of samples, each with Mn > 100 kg mol-1, of poly(cyclohexene carbonate) (PCHC), poly(vinyl-cyclohexene carbonate) (PvCHC), poly(ethyl-cyclohexene carbonate) (PeCHC, by hydrogenation of PvCHC), and poly(cyclopentene carbonate) (PCPC). All these materials are amorphous thermoplastics, with high glass transition temperatures (85 < Tg < 126 °C, by differential scanning calorimetry) and high thermal stability (Td > 260 °C). The cyclic ring substituents mediate the materials' chain entanglements, viscosity, and glass transition temperatures. Specifically, PCPC was found to have 10× lower entanglement molecular weight (Me)n and 100× lower zero-shear viscosity compared to those of PCHC, showing potential as a future thermoplastic. All these high molecular weight polymers are fully recyclable, either by reprocessing or by using the Mg(II)Co(II) catalyst for highly selective depolymerizations to epoxides and CO2. PCPC shows the fastest depolymerization rates, achieving an activity of 2500 h-1 and >99% selectivity for cyclopentene oxide and CO2.

Analysis of self-supporting conformal cooling channels additively manufactured by hybrid directed energy deposition for IM tooling

Additive manufacturing (AM) of injection moulding (IM) tools has attracted significant interest in the polymer manufacturing industry for quite some time. However, hybrid manufacturing (HM) using directed energy deposition (DED), which involves concurrent additive and subtractive manufacture, has not been a commonly used process for IM tooling manufacture. This is apparent despite several advantages over the prevalent laser-powder bed fusion (L-PBF) alternative, including higher build rate, lower cost and integrated machining to directly achieve higher tolerances and surface finish. A key reason for this low utilisation is the limited ability of DED processes to produce circular channel profiles typically used in IM tooling, due to stricter constraints on the manufacturability of overhanging geometry. To address this, a range of self-supporting IM cooling channel profiles suited for hybrid laser and powder-based DED manufacture are proposed in this work. Numerical and experimental evaluations are conducted of the cooling performance of several non-circular conformal cooling channel (NCCC) profiles to identify a profile which achieves the maximum heat transfer for a constant cross-sectional area and coolant flow rate. Experimental studies included AM builds to evaluate the DED manufacturability of the selected NCCC profile on a conformally cooled HM benchmark model, followed by cooling performance characterisation, including a comparison against a reference L-PBF manufactured benchmark model. In conclusion, a shape correcting factor is obtained using response surfaces. This factor is used to convert thermal performance calculations for non-circular profiles to a conventional circular channel profile to simplify the DED manufacturing process for non-circular IM cooling channels.

Influence of induced magnetic field and chemically reacting on hydromagnetic Couette flow of Jeffrey fluid in an inclined channel with variable viscosity and convective cooling: A Caputo derivative approach

In this study, the influence of induced magnetic field and chemically reacting on hydromagnetic generalized Couette flow of Jeffrey fluid in an inclined channel through a porous medium with variable viscosity and convective cooling has been investigated using the Caputo fractional order derivative operator. The mathematical formulation used for the hydromagnetic Couette flow of Jeffrey fluid takes into account the effects of viscous dissipation, Soret, and Dufour. The system of nonlinear partial differential equations governing the flow were solved numerically using the explicit finite difference method. The numerical results for the behavior of various physical parameter on the flow variables are obtained and represented graphically. Moreover, effects of the flow parameters on heat and mass transfer rates are obtained and discussed numerically through tabular forms. The graphical findings show that velocity, concentration, induced magnetic field, and thermal field profiles decline with progressively increment of Jeffrey parameter. The velocity, and temperature of the fluid decline with higher values of fluid viscosity parameter. An increase in the chemical reaction parameter recede the concentration field profiles while increase with raises the values of Soret number. Increasing Biot, and Dufour numbers significantly grows the thermal field profiles. Induced magnetic field grows with larger values of fluid viscosity parameter. The findings of this study are important due to its application in magnetohydrodynamics pumps, polymer manufacturing, fins designs, and food processing.

Chemical recycling of plastic waste for sustainable polymer manufacturing – A critical review

Chemical recycling has emerged as a promising approach to valorise non-recyclable, rejected, multi-layer, and contaminated plastic waste streams, such as packaging waste, aligning with the 3R's principles (reduce, reuse, and recycle). This paper critically evaluates various chemical recycling technologies, including pyrolysis, gasification, hydrothermal, and biological methods, which hold the potential to amend the global plastic pollution crisis while recovering valuable materials. Despite the potential of these methods, substantial challenges persist, including technological limitations, elevated capital costs, feedstock variability, energy consumption, and poor regulatory frameworks. The challenges and opportunities for future development are thoroughly discussed. Continuous research and development are vital for advancing chemical recycling technologies and transitioning towards a circular economy. A holistic approach, integrating not only chemical recycling, but also waste reduction, reuse, and other waste management strategies, is required to resolve the plastic waste crisis, and attain a more sustainable future.

Interlaminar Adhesion Study of Fused Filament Fabrication (FFF)-Printed Soft and Rigid Bilayer Structure with Composites

Multi-material Additive manufacturing (AM) has opened new opportunities for the creation of multifunctional structures that enables value-added structural product designs. Among the multi-material AM techniques, multi-nozzle fused filament fabrication which is a type of material extrusion technique is found to be the more popular choice for multi-material polymer fabrication. One major challenge of multi-material additive manufacturing of polymers is the poor mechanical strength at the interface of the dissimilar materials such as polylactic acid (PLA) and thermoplastic polyurethane (TPU) due to the lack of chemical affinity. Therefore, understanding the mechanical strength at the interface of these dissimilar materials becomes an important topic as it allows product designers to do necessary tweak to the design to compensate for the weaker link in the structural design. In this work, we investigated the tensile strength and the shear strength of different combinations of PLA and TPU and their respective nanocomposites, as well as the fatigue analysis of the bi-layer structures made of these dissimilar materials in a 3-point bending test configuration. Generally, when functional fillers or particles are added to the polymer in composites, they tend to adversely affect the interlaminar adhesion property and fatigue life of the soft-rigid bilayer structure. It was found, that the interlaminar tensile strength and the interlaminar shear strength can reduce as high as 44% and 78%, respectively, compared to the baseline samples with no fillers.

Adaptive Data-Driven Deep-Learning Surrogate Model for Frontal Polymerization in Dicyclopentadiene.

Frontal polymerization (FP) is a self-sustaining curing process that enables rapid and energy-efficient manufacturing of thermoset polymers and composites. Computational methods conventionally used to simulate the FP process are time-consuming, and repeating simulations are required for sensitivity analysis, uncertainty quantification, or optimization of the manufacturing process. In this work, we develop an adaptive surrogate deep-learning model for FP of dicyclopentadiene (DCPD), which predicts the evolution of temperature and degree of cure orders of magnitude faster than the finite-element method (FEM). The adaptive algorithm provides a strategy to select training samples efficiently and save computational costs by reducing the redundancy of FEM-based training samples. The adaptive algorithm calculates the residual error of the FP governing equations using automatic differentiation of the deep neural network. A probability density function expressed in terms of the residual error is used to select training samples from the Sobol sequence space. The temperature and degree of cure evolution of each training sample are obtained by a 2D FEM simulation. The adaptive method is more efficient and has a better prediction accuracy than the random sampling method. With the well-trained surrogate neural network, the FP characteristics (front speed, shape, and temperature) can be extracted quickly from the predicted temperature and degree-of-cure fields.

Accurate additive manufacturing of lightweight and elastic carbons using plastic precursors

Despite groundbreaking advances in the additive manufacturing of polymers, metals, and ceramics, scaled and accurate production of structured carbons remains largely underdeveloped. This work reports a simple method to produce complex carbon materials with very low dimensional shrinkage from printed to carbonized state (less than 4%), using commercially available polypropylene precursors and a fused filament fabrication-based process. The control of macrostructural retention is enabled by the inclusion of fiber fillers regardless of the crosslinking degree of the polypropylene matrix, providing a significant advantage to directly control the density, porosity, and mechanical properties of 3D printed carbons. Using the same printed plastic precursors, different mechanical responses of derived carbons can be obtained, notably from stiff to highly compressible. This report harnesses the power of additive manufacturing for producing carbons with accurately controlled structure and properties, while enabling great opportunities for various applications.

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation.

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

Recyclable, but not recycled—an indicator to quantify the environmental impacts of plastic waste disposal

With an exponential increase in the production and consumption of plastic products over the last few years, the predominantly linear (take-make-dispose) economy of the plastic life cycle has captured global attention. Even though plastic products offer versatile benefits with their properties across different sectors, with a global recycling rate of less than 10%, it is challenging to reduce the pollution generated by plastic waste. Also, the loss of resources due to the uncontrolled disposal of plastic waste has been projected to cause long-term negative effects on the environment. To ensure a better circularity of the plastic flows across the world, it is essential to design plastic products that have an adequate infrastructure to recover and recycle the waste no matter where they are used. The polymer manufacturers and the plastics converters must account for the environmental impacts of the resources lost in the environment due to the lack of recycling infrastructure as a part of Extended Producer Responsibility. This study introduces an indicator that accounts for the loss of resources and proposes for a better methodology to quantify the environmental impacts of polymers and plastic products, based on their recyclability and the availability of recycling infrastructure to handle them. By integrating the loss of resources with the environmental impacts of specific polymers used in specific plastic products, the stakeholders across the value chain have the choice to select the polymers and products that are actually recycled, thereby reducing their environmental impacts and increasing the circularity.

An airbrush 3D printer: Additive manufacturing of relaxor ferroelectric actuators

The additive manufacturing of electroactive polymer (EAP) devices poses significant challenges due to their distinct structure and dissimilar properties of their constituent materials. It requires deposition of multiple functional materials with different properties, achieving μm-scale resolution in layer thickness, and executing incremental deposition and curing steps while preserving the previously deposited functional material layers. This study introduces an airbrush 3D printer concept and employs it for fabricating EAP transducers. An airbrush 3D printer was constructed by adapting a standard extrusion printer platform and integrating it with a two fluid atomizer (i.e. an airbrush) as the deposition tool. A process was developed for printing of the bending P(VDF-TrFE-CTFE) actuators with carbon black electrodes, and actuators with a single and dual EAP layers were fabricated. The airbrush printer attained in-plane resolution of 0.5mm, thickness resolutions of 0.63 μm and allowed atomizing up to 7% P(VDF-TrFE-CTFE) solutions. The 18 mm × 4 mm EAP actuators achieved 340μm (440 Vpp) and 3.7 mm (400 Vpp, 104 Hz) tip deflections respectively in quasi-static and resonant operation. Airbrush printing therefore proved to be a robust method for printing precursor materials with a wide range of properties, and is anticipated to be a versatile approach for printing other passive and stimuli-responsive materials and devices.

Review on Frontal Polymerization Behavior for Thermosetting Resins: Materials, Modeling and Application.

The traditional curing methods for thermosetting resins are energy-inefficient and environmentally unfriendly. Frontal polymerization (FP) is a self-sustaining process relying on the exothermic heat of polymerization. During FP, the external energy input (such as UV light input or heating) is only required at the initial stage to trigger a localized reaction front. FP is regarded as the rapid and energy-efficient manufacturing of polymers. The precise control of FP is essential for several manufacturing technologies, such as 3D printing, depending on the materials and the coupling of thermal transfer and polymerization. In this review, recent progress on the materials, modeling, and application of FP for thermosetting resins are presented. First, the effects of resin formulations and mixed fillers on FP behavior are discussed. Then, the basic mathematical model and reaction-thermal transfer model of FP are introduced. After that, recent developments in FP-based manufacturing applications are introduced in detail. Finally, this review outlines a roadmap for future research in this field.