Additive manufacturing of self-healing polymers:  A comprehensive review of thermal and photo-activated systems

A.V. Santhana Babu; H.S. Philip; D. Jayabalakrishnan

doi:10.15625/2525-2518/23015

Author affiliations

Authors

A.V. Santhana Babu Department of Mechanical Engineering, Chennai Institute of Technology, Chennai-600069, India https://orcid.org/0009-0007-4353-5928
H.S. Philip Department of Mechanical Engineering, Chennai Institute of Technology, Chennai-600069, India
D. Jayabalakrishnan Department of Mechanical Engineering, Chennai Institute of Technology, Chennai-600069, India

DOI:

https://doi.org/10.15625/2525-2518/23015

Keywords:

3D printing, vat photo polymerization, extrusion

Abstract

Self-healing polymer is a polymeric material which, after the occurrence of any form of damage, such as cracks, scratches, or fractures, can independently or externally restore its original integrity and functionality without necessarily replacing the material itself. These polymers represent a transformative approach to enhance the service life and ensure the dependency of the systems, particularly in harsh environments where manual repairs are often impractical. These advanced materials are manufactured using additive manufacturing (AM) techniques that offer precise control over both structural properties and healing functionalities. This review highlights a thorough analysis of AM strategies applied to thermal-activated and photo-activated self-healing polymers and composites, with particular significance on their basic healing mechanisms. It highlights the distinct performance characteristics of these two systems, including activation conditions, healing efficiency, and their suitability for various aerospace applications. By focusing on thermal and photo-activated self-healing mechanisms, the review underscores their potential to reduce maintenance demands, enhance operational safety, and ensure long-term structural integrity. Furthermore, it identifies key challenges and future research opportunities, offering valuable insights for researchers and engineers working to integrate these innovative materials into next-generation aerospace systems.

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