Physical-modelling–driven process development of laser-induced freeform additive manufacturing for polymer-matrix composites

This work describes a novel additive manufacturing process able to deposit polymer matrix composites, from conceptualization to proof-of-concept. The process makes use of an indirect curing mechanism induced by laser heating of absorbing reinforcement particles within an optically transparent and colourless polymer matrix to produce self-standing freeform structures. This work presents a model-driven process design framework that constrains process development through first-principles descriptions of the governing optical and thermal laser-matter interactions. The model is used to derive fundamental system requirements in terms of material combination, laser characteristics, and achievable productivity. A cost analysis is also performed to assess the economic feasibility of the process. A proof-of-concept demonstration was provided using a curable polymer blend embedding copper microparticles. Process parameters were extracted from the developed theoretical model, demonstrating that crosslinking and structural solidification could be achieved through localized heating using a low-power blue laser (450 nm, 5 W). The results demonstrate the feasibility of this technological approach, which holds promise for future application in a variety of industrial sectors, from microelectronics to biomedical implant manufacturing.