Radical induced cationic frontal polymerisation (RICFP) is considered a promising low energy method for processing of fibre reinforced polymers (FRPs). Optimisation of the local heat balance between reinforcement, epoxy resin and the surrounding mould is required to pave the way for its adaptation to an industrial processing method for high volume fraction structural fibre reinforced composites. In this work, we investigate several methods to control the governing heat balance in RICFP-processing of FRPs. Heat generation was controlled by tuning the initiator concentration while limitation of heat losses using highly insulating moulds was found beneficial to the front characteristics and resulting curing degrees. An optimised mould configuration allowed for self-sustaining RICFP in FRPs with fibre volume fractions (V_fs) up to 45.8%, exceeding previously reported maxima of similar systems. A process window was moreover established relating the V_f and required heat generation to the potential formation of a self-sustaining or supported front.

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Radical Induced Cationic Frontal Polymerisation (RICFP) has recently been proposed as a promising strategy for processing of epoxide carbon fibre reinforced polymers. Control of the local heat balance is crucial towards the production of industrial-quality composites, which is typically achieved via controlling the heat generation. In this work we present a comprehensive overview of RICFP processing of cycloaliphatic epoxide composites with enhance heat insulation. The thermal initiating compound was identified as the main component to control heat generation, which correlated well with the front velocity. A processing window was defined as function of the fibre and initiator contents and composites with to 45.8% Vf were successfully produced. Optimisation of resulting mechanical properties was made possible by optimisation of the heat balance, with matrix glass transition temperatures of up to 187°C achieved for the used cycloaliphatic system. Post-curing was found beneficial to overcome suggested inhomogeneous curing due to the dual-scale nature of fabrics. @en