Modeling for Frontal Polymerization Curing Process - STTR Topic DON26TZ01-NV002

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This topic was temporarily posted by the Department of War SBIR Program on March 2nd 2026 and removed the following day.
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Funding Amount:

Est. $240,000

Deadline to Apply:

Est. April 29th, 2026.

Objective:

Develop a multiphysics model or toolset to predict frontal polymerization phenomena and to optimize the resin additives (e,g., catalyst, inhibitor, etc.) for an optimized cure with less distortion or residual stress, while ensuring that the front does not self-extinguish.

Description:

Frontal polymerization is the process of curing a resin monomer into a polymer with a localized self-sustaining and moving reaction zone. Frontal polymerization has many benefits over traditional resin cure methods, such as reduced cure time from many hours to seconds or minutes [Refs 1,-2], a significant reduction of the energy required to cure (in some cases over 99.5%) [Ref 3], and reduced cost associated with curing a resin [Ref 3].

Frontal polymerization has many potential applications such as increasing cure percentage for thermoset additive manufacturing processes without requiring a post cure, rapid manufacturing of composite structures, and rapid composite curing for accelerated repairs of composite structures.

Frontal polymerization is a very boundary condition dependent process. Changes in boundary conditions, initial conditions (including temperature and initiation methods), resin formulations, resin or composite thickness, as well as the addition of reinforced fibers or materials can drastically affect characteristics like front velocity, front temperature, and whether a front is sustained or terminated. This can make it challenging to predict and synthesize resin systems that can sustain a frontally polymerized cure with different initiation methods, environmental conditions, composite/resin thicknesses, and reinforcement materials.

Currently, phenomenological multiphysics modeling efforts for frontal polymerization are limited to 1D, 2D, or small 3D models, since they are very computationally demanding due to the highly nonlinear coupling of the governing equations and short timescales required for accurate solution convergence. Furthermore, many models do not predict the mechanical response resulting from the frontal polymerization process (i.e., warpage or residual stress of the polymer caused by the frontal polymerization process). Surrogate modeling can drastically reduce the time to simulate a front but often requires training to create the surrogate model in the form of many finite element analyses or experiments that can be very time consuming. Recently a mechanism-based approach has been created, allowing for prediction of frontal polymerization phenomena without requiring differential scanning calorimetry (DSC) testing to obtain properties for different resin formulations [Ref 4].

This STTR topic calls for development of a model or toolset to predict characteristics of the frontal polymerization process such as front temperature, front velocity, and cure percentage, as well as the resulting effects from the frontal polymerization process such as warpage, residual stress, or post cure mechanical strength. The model should work for multiple initiation methods (i.e., a point initiation of the front, line initiation, and planar initiation for the front (for simulating a point heat source, a line/wire heat source, and a planar heat source). The model should also be scalable, allowing for simulation of different/larger geometries without detrimental increases in computational time. This topic falls under the NAWCAD STTR focus area for in situ material detection and repair solutions.

Who will win?

If you can achieve the objective above better than any other company on the market, you have a very high-likelihood of success and should apply.

Who is eligible to apply?

Any company that meets the following criteria:

• For-profit company

• U.S.-owned and controlled.

• 500 or fewer employees (including affiliates)

How Can BW&CO Help?

1) End-to-end support including, strategy, writing of the full proposal, and administrative & compliance support.

2) Proposal strategy and review.

3) Administrative & compliance support.

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