Frontal Polymerization for the Rapid Obtainment of Polymer Composites

Among the different polymerization techniques, frontal polymerization (FP) has gained high interest from the scientific community because of its peculiar characteristics: in particular, compared to classic polymerization reactions, FP allows for a better exploitation of the heat of polymerization involved, without requiring any external energy input apart from an initial photo or thermal ignition that triggers the reaction. The latter usually propagates in a few tenths of seconds or (at most) minutes through a hot self-sustaining polymerization front, giving rise to the formation of fully cured thermosetting networks or thermoplastic polymers. Furthermore, different polymerization mechanisms can be involved in FP reactions, comprising cationic or anionic, ring-opening metathesis, and free-radical polymerization, among others. Further, it is possible to run FP reactions in bulk, in solution, or even using solid monomers if they are melted at the temperature of the front, notwithstanding the possibility of using reactive systems containing fillers or fiber/fabric reinforcements. In this context, the use of FP is becoming very important also for the design and production of advanced (nano)composite materials, saving processing time and achieving the completeness of the curing reaction, even in the presence of high filler/reinforcement loadings. Therefore, this mini-review aims to provide the reader with the basics of FP and its main peculiarities, even in the context of preparing high-performing composites. In this respect, some recent case studies witnessing the potentialities of frontal polymerization for the design of advanced (nano)composite systems will be elucidated. Finally, some perspectives about possible future developments will be proposed.