10031350Reactive Fusion - Revolutionary Technology for 3D Printing Polyurethane ProductClosedCollaborative R&DInnovate UKReactive Fusion (RF) is a novel Additive Manufacturing (3D Printing) process based on the principle of polymer powder deposition followed by the deposition of a monomeric / oligomeric fluid that infiltrates the powder layer and provides chemical bonding, between the deposited particles and the monomers/oligomers themselves, creating a continuous and homogenous material deposition. It has the potential to offer industry inkjet based 3D printing technique's processing speeds, combined with traditional polymer product production methods (moulding etc) levels of product strength and wide material choices. This process is similar to binder jetting based AM techniques and HP's multi-jet fusion system, however instead of using binders or fusion agents to melt the powder together, RF used a special ink to combine powder via chemical covalent bonding in order to achieve more homogeneous properties throughout a printed product. RF technology offers a patented, platform 3D printing process that removes the major current problem of AM polymer product delamination, and which prints products at high speed and low cost, delivers complex product structure capability and accesses the full properties of PU based polymers that is only currently available via traditional, long lead-time, expensive injection tooling and moulding. Our market research has shown the technology is of interest to multiple industrial sector with unmet AM product needs, several early technology adopters have been identified - potential markets include Automation/Robotics, Prosthetic/Orthotics, Dentistry, with further commercial interest evident in Automotive, Medical device, Footwear and the Sports industry sectors. We believe RF can displace a significant proportion of current traditional polyurethane product production, where use of AM is economical/feasible. Reactive Fusion Ltd has the expertise and drive to develop and commercialize its innovative RF technology in terms of chemistry, equipment and services based on several years of research from the University of Nottingham. The projects key objectives are to move the technology from lab scale, to industrial scale, creating product and process demonstrators for potential customers and early stage investors. Using subcontractors with extensive expertise in scaling up AM materials and building/modifying AM machinery/components, will support the project to achieve its goals with the resources proposed and with a managed level of risk.