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Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title In-Situ Thermal Monitoring of the Laser-Powder Bed Fusion Process for Polyurethane-Modified Epoxy Thermosetting Polymer Networks
Author(s) Jairam Raigar, Rajkumar Velu, Hadi Bakhshi
On-Site Speaker (Planned) Jairam Raigar
Abstract Scope Laser-based powder bed fusion (L-PBF) of thermoplastics requires high processing temperatures (173–250 °C), which can lead to thermal aging and reduced part performance. Incorporation of thermosetting polymers offers a low-temperature alternative via in-situ crosslinking but is limited by rapid gelation and poor process control. This study experimentally investigates thermoplastic polyurethane (TPU)-modified epoxy powders for L-PBF using a selective laser polymerization (SLP) approach. TPU/epoxy blends (25/75, 50/50, 75/25 wt%) were characterized using SEM, DSC, and FTIR to assess morphology, thermal behavior, and processability. Single-layer SLP experiments combined with in-situ infrared thermography revealed improved powder flowability, melt stability, and layer uniformity with TPU addition. The 50/50 composition showed optimal performance, achieving effective melt coalescence and controlled epoxy curing at 0.304 J/mm˛. Results highlight the role of thermal gradients and process control in forming stable interpenetrating networks, demonstrating the potential of reactive L-PBF for advanced thermoset additive manufacturing.
Proceedings Inclusion? Planned: Post-meeting proceedings

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Thermal Annealing-Induced Property Enhancement in Additively Manufactured PC-CF Composites
Thermal Modeling of Drop Placement Strategies for Multi-Nozzle Molten Metal Jetting
Thermal Optimization to Enable SMARTT Toolpaths for Efficient and Effective Multi-Robot DED
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Towards Field Driven Design of Cellular Materials for Energy Absorption: Modeling and Simulation of Variable-Thickness Schwarz-P TPMS Structures
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Volumetric Additive Repair: Near-Real Time Selective Multi-Axis Toolpathing
WAAM Development Cell with Adaptive Trajectory Control
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Wire-Arc Additive Manufacturing Process Development for Martensitic Stainless Steels
Wire Arc Additive Manufacturing of Functionally Graded Materials
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Working Curve Model to Enable Precise Curing of Functionally Graded Resin Systems
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