In certain embodiments, the process comprises depositing a lead-out bridge layer of thermosetting material and depositing a lead-out block layer of thermosetting material.

In certain embodiments, the present disclosure is directed to a to three-dimensional (3D) object production process comprising: providing a thermoset printing apparatus comprising: a mixing chamber to receive and mix at least a first reactive component and a second reactive component to provide a thermosetting material, an extrusion nozzle to deliver the thermosetting material to form a 3D object, at least one actuator coupled to the extrusion nozzle to move the extrusion nozzle when delivering the thermosetting material to form the 3D object, and a controller comprising one or more processors and coupled to the extruded thermoset printing apparatus, and depositing the thermosetting material to form the 3D object, wherein the depositing comprises depositing a main part layer of thermosetting material, depositing a lead-out bridge layer of thermosetting material, and depositing a lead-out block layer of thermosetting material.

In certain embodiments, the process comprises depositing a lead-in block layer and depositing a lead-in bridge layer of thermosetting material.

In certain embodiments, the present disclosure is directed to a process for three-dimensional (3D) printing, comprising: depositing a lead-in block layer of thermosetting material, depositing a lead-in bridge layer of thermosetting material, and depositing a main part layer of thermosetting material. In certain embodiments, the process comprises depositing a lead-out bridge layer of thermosetting material and depositing a lead-out block layer of thermosetting material.

In certain embodiments, the present disclosure is directed to a process for three-dimensional (3D) printing, comprising: depositing a main part layer of thermosetting material, depositing a lead-out bridge layer of thermosetting material, and depositing a lead-out block layer of thermosetting material. In certain embodiments, the process comprises depositing a lead-in block layer and depositing a lead-in bridge layer of thermosetting material.

In certain embodiments, the process comprises depositing an exterior of the lead-in block layer. In certain embodiments, the process comprises depositing an exterior of the lead-out block layer. In certain embodiments, the process comprises depositing thermosetting material on an exterior of the lead-in block and/or the lead-out block before depositing thermosetting material inside the exterior. Put another way, thermosetting material can be deposited on a perimeter of the lead-in block and/or lead-out block layer before the area of the layer is filled in.

In certain embodiments, a last bead of the lead-in bridge layer can be adjacent to a first bead of the main part layer. In certain embodiments, a last bead of the main part layer can be adjacent to a first bead of the lead-out bridge layer. In certain embodiments, the connection between the lead-in block layer and/or the lead-out block layer and the main part layer can be a single bead. In certain embodiments, the connection between the lead-in bridge layer and/or the lead-out bridge layer and the main part layer can be more than one bead. In certain embodiments, a portion of the lead-in bridge layer and/or the lead-out bridge layer that can connect to the main part layer is thinner and/or narrower than a different portion of the lead-in bridge layer and/or the lead-out bridge layer. Put another way, the connection between the lead-in bridge layer and/or the lead-out bridge layer can be the thinnest or narrowest portion of the lead-in bridge layer and/or the lead-out bridge layer. In certain embodiments, a portion of the lead-in bridge layer and/or the lead-out bridge layer that can connect to the main part layer is not thinner and/or not narrower than a different portion of the lead-in bridge layer and/or the lead-out bridge layer.

In certain embodiments, the process comprises a gap between the lead-in bridge layer and the main part layer and/or a gap between the main part layer and the lead-out bridge layer. In certain embodiments, the process comprises no gap between the lead-in bridge layer and the main part layer and/or a gap between the main part layer and the lead-out bridge layer.

In certain embodiments of the process, the linear extrusion density of the depositing of the lead-in block layer, the lead-in bridge layer, the main part layer, the lead-out bridge layer, and/or the lead-out block layer can be constant. In certain embodiments, the linear extrusion density of the depositing of the lead-in block layer, the lead-in bridge layer, the main part layer, the lead-out bridge layer, and/or the lead-out block layer can be non-constant. As used herein. “linear extrusion density” refers to the amount of material deposited per distance that is translated by the printer tip. The linear extrusion density can be described in E/mm or g/mm. E/mm can be a result of the G-Code and settings on the printer; g/mm can represent the physical behavior. E/mm describes the E value that the printer sees (a command to move the extruder axis a specified distance), while the g/mm describes the physical behavior of the printer (how much material is extruded). Depending on how the printer is configured using the G-Code, the extruder can pump out different masses or volumes for the same E/mm. Combined with bead width, E/mm can represent the layer height. Grams extruded per millimeter travelled can be a direct quantity of the print behavior verses the specific settings of the printer.

In certain embodiments, the linear extrusion density and bead width are set such that the layer height of the lead-in block is the same as the layer height in the main part. If the layer height of the lead-in or lead-out block is too high, material can be accumulated on the extrusion tip, which may damage or introduce flaws in the part. In certain embodiments, the linear extrusion density can be from about 0.0001 g/mm to about 0.001 g/mm, including from about 0.00069 to about 0.00092 g/mm and from about 0.0005 g/mm to about 0.0008 g/mm.

In certain embodiments, the process can comprise depositing the thermosetting material using any bead spacing. In certain embodiments, the depositing compromises a bead spacing of the thermosetting material from about 0.1 mm to about 2 mm. In certain embodiments, the depositing compromises a bead spacing of the thermosetting material from about 0.2 mm to about 1 mm. In certain embodiments, the depositing compromises a bead spacing of the thermosetting material from about 0.4 mm to about 0.8 mm.

In certain embodiments, the depositing compromises a bead spacing of the thermosetting material less than about 1 mm. In certain embodiments, the depositing compromises a bead spacing of the thermosetting material less than about 0.8 mm. In certain embodiments, the depositing compromises a bead spacing of the thermosetting material less than about 0.7 mm. In certain embodiments, the bead spacing can be about 0.1 mm, about 0.2 mm, about 0.3 mm, about 0.4 mm, about 0.5 mm, about 0.6 mm, about 0.7 mm, about 0.8 mm, about 0.9 mm, about 1 mm, about 1.2 mm, about 1.4 mm, about 1.6 mm, about 1.8 mm, or about 2 mm, or any ranges between the specified values.

In certain embodiments, the process can comprise depositing the thermosetting material using any translation speed. In certain embodiments, the depositing compromises a translation speed of at least about 100 mm/min. In certain embodiments, the depositing compromises a translation speed of at least about 500 mm/min. In certain embodiments, the depositing compromises a translation speed of at least about 1000 mm/min. In certain embodiments, the depositing compromises a translation speed of at least about 5000 mm/min. In certain embodiments, the depositing compromises a translation speed of from about 100 mm/min to about 5000 mm/min. In certain embodiments, the depositing compromises a translation speed of from about 800 mm/min to about 2500 mm/min. In certain embodiments, the depositing compromises a translation speed of from about 500 mm/min to about 1000 mm/min.

In certain embodiments, the translation speed can be about 25 mm/min, about 50 mm/min, about 100 mm/min, about 25 mm/min, about 50 mm/mm, about 100 mm/min, about 25 mm/min, about 50 mm/min, about 100 mm/min, about 200 mm/min, about 300 mm/min, about 400 mm/min, about 500 mm/min, about 600 mm/min, about 700 mm/min, about 800 mm/min, about 900 mm/min, about 1000 mm/min, about 1500 mm/min, about 2000 mm/min, about 2500 mm/min, about 3000 mm/min, about 3500 mm/min, about 4000 mm/min, about 4500 mm/min, about 5000 mm/min, about 5500 mm/min, about 6000 mm/min, about 6500 mm/min, about 7000 mm/min, about 7500 mm/min, about 8000 mm/min, about 8500 mm/min, about 9000 mm/min, about 9500 mm/min, about 10000 mm/min, or any ranges between the specified values.

In certain embodiments, a flow rate of the thermosetting material through the extrusion nozzle can be adjusted to optimize the flow rate through the extrusion nozzle. Depending on the properties of the reactive components and the geometry of the desired final 3D product, the flow rate adjustment can vary. As used herein, the term “flow rate through the extrusion nozzle” means a volumetric flow rate, or a volume of material in mm³that is pushed through the nozzle in a second. The rate can vary depending on the tip diameter. In certain embodiments, the maximum rate can be set by the strength of the pump on the printer. In certain embodiments, the flow rate can controlled by the setting the pump displacement.

In certain embodiments, the flow rate through the extrusion nozzle can be from about 0.1 mm³/s to about 200 mm³/s. In certain embodiments, the flow rate can be from about 1 mm³/s to about 100 mm³/s. In certain embodiments, the flow rate can be from about 5 mm³/s to about 50 mm³/s. In certain embodiments, the flow rate can be about about 0.1 mm³/s, about 0.5 mm³/s, about 1 mm³/s, about 5 mm³/s, about 10 mm³/s, about 15 mm³/s, about 20 mm³/s, about 25 mm³/s, about 30 mm³/s, about 35 mm³/s, about 40 mm³/s, about 45 mm/s, about 50 mm³/s, about 100 mm³/s, about 150 mm³/s, about 200 mm³/s, about 500 mm³/s, about 1000 mm³/s, or any ranges between the specified values. In certain embodiments, the flow rate of the material, combined with the volume of the mixing chamber, can set the extent of reaction of the material at the time that it leaves the nozzle. For example, if the printer is printing at 0.1 mm³/s and the mixer has a volume of 2 mm³, then the reaction mixture can be, on average, about 20 seconds into its reaction. If the flow rate is decreased to 0.01 mm³/s, then the reaction mixture can be, on average, about 200 seconds into its reaction.

In certain embodiments, the thermosetting material can be have a particular viscoelasticity. Viscoelastic materials can have both solid-like and liquid-like properties. In certain embodiments, viscoelasticity can be the ratio of storage modulus to loss modulus. If the thermosetting material is highly elastic, then once a flow stop command is executed, the material can spring back into the printhead. If the material is highly viscous, then the material can flow until the pressure that was used to force extrusion is relaxed within the material. This viscous response can be considered the thermosetting material's latency. The speed of the response of the material to a force change from positive pressure to light suction can depend on the viscosity of the thermosetting material. In certain embodiments, a thermosetting material can flow unless a light suction is supplied. In certain embodiments, the viscoelasticity can have a G′/G″ (often referred to as tan delta) greater than about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8, about 0.9 or about 1, or any ranges between the specified values.

In certain embodiments, the process comprises removing the lead-in block layer, lead-in bridge layer, lead-out bridge layer, and/or lead-out bridge layer. In certain embodiments, the removing can be by cutting and/or sanding.

In certain embodiments, at least one printing parameter can be the same between each of the depositing of the lead-in block layer, the lead-in bridge layer, the main part layer, the lead-out bridge layer, and/or the lead-out block layer. In certain embodiments, at least one printing parameter can be different between each of the depositing of the lead-in block layer, the lead-in bridge layer, the main part layer, the lead-out bridge layer, and/or the lead-out block layer. In certain embodiments, at least one printing parameter can be the same between the layer and an at least second layer. In certain embodiments, at least one printing parameter can be different between the layer and an at least second layer. As a non-limiting example, the translation speed can be different between the lead-in bridge layer and the main part layer. As a non-limiting example, the flow rate can be different between the main part layer and the lead-out bridge layer.

In certain embodiments, the thermoset printing apparatus can comprise use of a pump. In certain embodiments, the thermoset printing apparatus can comprise a suction pump. In certain embodiments, the process comprises applying suction during the depositing.

In certain embodiments, the suction can be applied for any amount of time. In certain embodiments, the process comprises applying suction for at least about 1 second. In certain embodiments, the process comprises applying suction for at least about 10 seconds. In certain embodiments, the process comprises applying suction for at least about 30 seconds. In certain embodiments, the process comprises applying suction for at least about 1 minute. In certain embodiments, the process comprises applying suction for from about 1 second to about 5 minutes. In certain embodiments, the process comprises applying suction for from about 5 seconds to about 1 minute. In certain embodiments, the process comprises applying suction for from about 10 second to about 30 seconds.

In certain embodiments, the process comprises applying suction for about 1 second, about 2 seconds, about 3 seconds, about 4 seconds, about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, about 20 seconds, about 21 seconds, about 22 seconds, about 23 seconds, about 24 seconds, about 25 seconds, about 26 seconds, about 27 seconds, about 28 seconds, about 29 seconds, about 30 second, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 60 second, about 90 seconds, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, or any ranges between the specified values.

In certain embodiments, the process comprises use of a support. As used herein, the term “support” means an object or material that can provide stability during 3D printing.

In certain embodiments, the process comprises depositing a support material during the depositing of the thermosetting material. In certain embodiments, the support material can be an olefinic material. In certain embodiments, the olefinic material can be a polyalkylene, such as polyethylene and/or polypropylene. In certain embodiments, the support can be polylactic acid. In certain embodiments, the support can be acrylonitrile butadiene styrene (ABS). In certain embodiments, the support can be an ABS-like UV-curing rapid resin, such as Elegoo Standard resin. In certain embodiments, the support can be a silicone mat.

In certain embodiments, the support can be coated. In certain embodiments, the support can be coated with a release agent, such as a mold release agent. In certain embodiments, the support can be coated with a paste wax, such as a finish paste wax. In certain embodiments, the support is untreated.

In certain embodiments, the support can be 3D printed with a fused filament fabrication (FFF) printer. In certain embodiments, the support can be 3D printed with a stereolithography (SLA) printer. In certain embodiments, the support can be co-3D printed with the depositing of the 3D object having overhang. In certain embodiments, the support can be 3D printed prior to depositing the 3D object having overhang.

In certain embodiments, the process comprises removing the support. In certain embodiments, the removing can be by melting.

In certain embodiments, the present disclosure is directed to a 3D object produced by the disclosed processes. In certain embodiments, the present disclosure is directed to a 3D object produced using the disclosed systems.

In certain embodiments, the present disclosure is directed to a 3D object comprising: a lead-in block, a lead-in bridge, and a main part. In certain embodiments, the 3D object comprises a lead-out bridge and a lead-out block.

In certain embodiments, the present disclosure is directed to a 3D object comprising: a main part, a lead-out bridge, and a lead-out block. In certain embodiments, the 3D object comprises a lead-in block and a lead-in bridge.

Thermosetting Material

The thermosetting material according to embodiments of the disclosure can be composed of any number of materials.

In certain embodiments, the thermosetting material can be an isocyanate, an isocyanate prepolymer, a urethane, a urea-containing polymer, a polyol prepolymer, an amine prepolymer, a polyol containing at least one terminal hydroxyl group, a polyamine containing at least one amine that contains an isocyanate reactive hydrogen, or mixtures thereof.

In certain embodiments, the thermosetting material can be an isocyanate. In certain embodiments, the thermosetting material can be an isocyanate prepolymer. In certain embodiments, the thermosetting material can be a urethane. In certain embodiments, the thermosetting material can be a urea-containing polymer. In certain embodiments, the thermosetting material can be a polyol prepolymer. In certain embodiments, the thermosetting material can be an amine prepolymer. In certain embodiments, the thermosetting material can be a polyol containing at least one terminal hydroxyl group. In certain embodiments, the thermosetting material can be a polyamine containing at least one amine that contains an isocyanate reactive hydrogen.

In certain embodiments, the thermosetting material can be a urethane and/or urea-containing polymer. In certain embodiments, a urethane and/or urea-containing polymer can be a polymer which contains urethane groups (—NH—(C═O)—O—) as part of the polymer chain. The urethane linkage can be formed by reacting isocyanate groups (—N═C═O) with hydroxyl groups (—OH). A polyurethane can be produced by the reaction of an isocyanate containing at least two isocyanate groups per molecule with a compound having terminal hydroxyl groups. In certain embodiments, an isocyanate having, on average, two isocyanate groups per molecule can be reacted with a compound having, on average, at least two terminal hydroxyl groups per molecule.

In certain embodiments, a urethane and/or urea-containing polymer can be a polymer which contains urea groups (—NH—(C═O)—NH—) as part of the polymer chain. A urea linkage can be formed by reacting isocyanate groups (—N═C═O) with amine groups (e.g., —N(R′)₂), where each R′ is independently hydrogen or an aliphatic and/or cyclic group (typically a (C₁-C₄)alkyl group)). A polyurea can be produced by the reaction of an isocyanate containing at least two isocyanate groups per molecule with a compound having terminal amine groups.

In certain embodiments, an aliphatic group can be a saturated or unsaturated linear or branched hydrocarbon group. This term can encompass alkyl (e.g., —CH₃) (or alkylene if within a chain such as —CH₂—), alkenyl (or alkenylene if within a chain), and alkynyl (or alkynylene if within a chain) groups, for example. In certain embodiments an alkyl group can be a saturated linear or branched hydrocarbon group including, for example, methyl, ethyl, isopropyl, t-butyl, heptyl, dodecyl, octadecyl, amyl, 2-ethylhexyl, and the like. In certain embodiments, an alkenyl group can be an unsaturated, linear or branched hydrocarbon group with one or more carbon-carbon double bonds, such as a vinyl group. In certain embodiments, an alkynyl group can be an unsaturated, linear or branched hydrocarbon group with one or more carbon-carbon triple bonds. Unless otherwise indicated, an aliphatic group typically contains from 1 to 30 carbon atoms. In certain embodiments, the aliphatic group can contain 1 to 20 carbon atoms, 1 to 10 carbon atoms, 1 to 6 carbon atoms, 1 to 4 carbon atoms, or 1 to 3 carbon atoms.

In certain embodiments, a cyclic group can be a closed ring hydrocarbon group that is classified as an alicyclic group, aromatic group, or heterocyclic group, and can optionally include an aliphatic group. In certain embodiments, an alicyclic group can be a cyclic hydrocarbon group having properties resembling those of aliphatic groups. In certain embodiments, an aromatic group or aryl group can be a mono- or polynuclear aromatic hydrocarbon group. In certain embodiments, a heterocyclic group can be a closed ring hydrocarbon in which one or more of the atoms in the ring is an element other than carbon (e.g., nitrogen, oxygen, sulfur, etc.). Unless otherwise specified, a cyclic group can have 6 to 20 carbon atoms, 6 to 18 carbon atoms, 6 to 16 carbon atoms, 6 to 12 carbon atoms, or 6 to 10 carbon atoms.

In certain embodiments, a urethane and/or urea-containing polymer can be a polymer that contains both urethane and urea groups as part of the polymer chain. A polyurethane/polyurea can be produced by the reaction of an isocyanate containing at least two isocyanate groups per molecule with a compound having terminal hydroxyl groups and a compound having terminal amine groups. In certain embodiments, a polyurethane/polyurea can be produced by the reaction of an isocyanate containing at least two isocyanate groups per molecule with a compound having terminal hydroxyl groups and terminal amine groups (e.g., a hydroxyl-amine such as 3-hydroxy-n-butylamine (CAS 114963-62-1)). A reaction to make a polyurethane, a polyurea, or a polyurethane/polyurea can include other additives, including but not limited to, a catalyst, a chain extender, a curing agent, a surfactant, a pigment, or a combination thereof.

An isocyanate, which can be considered a polyisocyanate, can have the structure R—(N═C═O)_n, where n can be at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, or at least 8, and where R can be an aliphatic and/or cyclic group. In certain embodiments, an isocyanate can have an n that is equivalent to n in methylene diphenyl diisocyanate (MDI). In certain embodiments, the isocyanate can be a di-isocyanate (e.g., R—(N═C═O)₂or (O═C═N)—R—(N═C═O)).

Examples of isocyanates can include, but are not limited to, methylene diphenyl diisocyanate (MDI) and toluene diisocyanate (TDI). Examples of MDI can include, but are not limited to, monomeric MDI, polymeric MDI, and isomers thereof. Examples of isomers of MDI having the chemical formula C₁₅H₁₀N₂O₂can include, but are not limited to, 2,2′-MDI, 2,4′-MDI, and 4,4′-MDI. Examples of isomers of TDI having the chemical formula C₉H₆N₂O₂can include, but are not limited to, 2,4-TDI and 2,6-TDI. In certain embodiments, examples of isocyanates can include, but are not limited to, monomeric diisocyanates and blocked polyisocyanates. In certain embodiments, examples of monomeric diisocyanates can include, but are not limited to, hexamethylene diisocyanate (HDI), methylene dicyclohexyl diisocyanate or hydrogenated MDI (HMDI), and isophorone diisocyanate (IPDI). In certain embodiments, an example of an HDI can be hexamethylene-1,6-diisocyanate. In certain embodiments, an example of an HMDI can be dicyclohexylmethane-4,4′-diisocyanate. Blocked polyisocyanates can be based on HDI or IDPI. In certain embodiments, examples of blocked polyisocyanates can include, but are not limited to, HDI trimer, HDI biuret, HDI uretidione, and IPDI trimer.

In certain embodiments, examples of isocyanates can include, but are not limited to, aromatic diisocyanates, such as a mixture of 2,4- and 2,6-tolylene diisocyanates (TDI), diphenylmethane-4,4′-diisocyanate (MDI), naphthalene-1,5-diisocyanate (NDI), 3,3′-dimethyl-4,4′-biphenylene diisocyanate (TODI), crude TDI, polymethylenepolyphenyl isocyanurate, crude MDI, xylylene diisocyanate (XDI), and phenylene diisocyanate; aliphatic diisocyanates, such as 4,4-methylene-biscyclohexyl diisocyanate (hydrogenated MDI), hexamethylene diisocyanate (HMDI), isophorone diisocyanate (IPDI), and cyclohexane diisocyanate (hydrogenated XDI); and modified products thereof, such as isocyanurates, carbodiimides and allophanamides.

In certain embodiments, a compound having terminal hydroxyl groups (R—(OH)_n), where n is at least 2 (referred to herein as “di-functional”), at least 3 (referred to herein as “tri-functional”), at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, and 10, where R is an aliphatic and/or cyclic group, can be a “polyol.” In certain embodiments a polyol mixture can include a small amount of mono-functional compounds having a single terminal hydroxyl group.

In certain embodiments, examples of polyols can include, but are not limited to, polyester polyols and polyether polyols. In certain embodiments, examples of polyester polyols can include, but are not limited to, those built from condensation of acids and alcohols. In certain embodiments, examples can include those built from phthalic anhydride and diethylene glyol, phthalic anhydride and dipropylene glycol, adipic acid and butanediol, and succinic acid and butane or hexanediol. In certain embodiments, polyester polyols can be semi-crystalline. In certain embodiments, examples of polyether polyols can include, but are not limited to, those built from polymerization of an oxide such as ethylene oxide, propylene oxide, or butylene oxide from an initiator such as glycerol, dipropylene glycol, TPG (tripropylene glycol), castor oil, sucrose, or sorbitol.

In certain embodiments, examples of polyols can include, but are not limited to, polycarbonate polyols and lactone polyols such as polycaprolactone. In certain embodiments, a compound having terminal hydroxyl groups (R—(OH)_n) can have a molecular weight (calculated before incorporation of the compound having terminal hydroxyl groups into a polymer) of from about 200 Daltons to about 20,000 Daltons, such as from about 200 Daltons to about 10,000 Daltons.

In certain embodiments, a compound having terminal amine groups (e.g., R—(N(R′)₂)_n), where n can be at least 2, at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, and 10, where R can be an aliphatic and/or cyclic group, and where each R′ can be independently hydrogen or an aliphatic and/or cyclic group (e.g., a (C₁-C₄)alkyl group), can be referred to as a “polyamine.” In certain embodiments, a polyamine mixture can include a small amount of mono-functional compounds having a single terminal amine group.

In certain embodiments, a suitable polyamine can be a diamine or triamine, and can be either a primary or secondary amine. In certain embodiments, a compound having terminal amine groups can have a molecular weight (calculated before incorporation of the compound having terminal hydroxyl groups into a polymer) of from about 30 Daltons to about 5000 Daltons, such as from about 40 Daltons to about 400 Daltons.

In certain embodiments, examples of polyamines can include, but are not limited to, diethyltoluene diamine, di-(methylthio)toluene diamine, 4,4′-methylenebis(2-chloroaniline), and chain extenders available under the trade names LONZACURE L15, LONZACURE M-CDEA, LONZACURE M-DEA, LONZACURE M-DIPA, LONZACURE M-MIPA, and LONZACURE DETDA.

In certain embodiments, examples of suitable polyamines can include, but are not limited to, ethylene diamine, 1,2-diaminopropane, 1,4-diaminobutane, 1,3-diaminopentane, 1,6-diaminohexane, 2,5-diamino-2,5-dimethylhexane, 2,2,4- and/or 2,4,4-trimethyl-1,6-diaminohexane, 1,11-diaminoundecane, 1,12-diaminododecane, 1,3- and/or 1,4-cyclohexane diamine, I-amino-3,3,5-trimethyl-5-aminomethyl-cyclohexane, 2,4- and/or 2,6-hexahydrotoluylene diamine, 2,4′ and/or 4,4′-diaminodicyclohexyl methane, and 3,3′-dialkyl-4,4′-diamino-dicyclohexyl methanes such as 3,3′-dimethyl-4,4-diamino-dicyclohexyl methane and 3,3′-diethyl-4,4′-diaminodicyclohexyl methane; aromatic polyamines such as 2,4- and/or 2,6-diaminotoluene and 2,4′ and/or 4,4′-diaminodiphenyl methane; and polyoxyalkylene polyamines.

In certain embodiments, the term polyol and/or polyamine mixture can be a mixture of one or more polyols of varied molecular weights and functionalities, one or more polyamines of varied molecular weights and functionalities, or a combination of one or more polyols and one or more polyamines.

In certain embodiments, the thermosetting material can comprise at least one reactive component. In certain embodiments, the thermosetting material can comprise at least two reactive components. In certain embodiments, the thermosetting material can comprise at least three reactive components. In certain embodiments, the thermosetting material can comprise at least four reactive components.

In certain embodiments, the thermosetting material can be prepared by methods disclosed in WO 2018/106822 and PCT/US2018/064323, each of which is incorporated in its entirety herein. In certain embodiments, a method for making a thermosetting material, such as a urethane and/or urea-containing polymer thermoset product, can include introducing first and second reactive components into a mixing chamber. In certain embodiments, the first reactive component can include an isocyanate and the second reactive component can include a polyol and/or polyamine mixture. In certain embodiments, the first reactive component can include an isocyanate and the second reactive component can include a polyol. In certain embodiments, the first reactive component can include an isocyanate and the second reactive component can include a polyamine. In certain embodiments, the first reactive component can include an isocyanate and the second reactive component can include a polyol and a polyamine. The first and second reactive components can have certain characteristics including, but not limited to, viscosity, reactivity, and chemical compatibility.

In certain embodiments, the thermosetting material can be a solid thermosetting material.

In certain embodiments, the thermosetting material can be a foam thermosetting material.