Epoxy filled with nylon powder—An approach to reduce void formation via fused particle method

Abstract In the quest for superior materials, especially in industrial applications demanding strength, stiffness, low density, and cost‐efficiency, composite materials have emerged as game changers. Combining a polymer matrix with reinforcement materials, they hold great promise. However, the challenge of particle agglomeration looms large, especially at high loadings. Particle agglomeration disrupts filler distribution and gives rise to voids in polymer composites. This study investigates the fusion behavior of agglomerated Nylon particles and their influence on Nylon/epoxy composites. Using epoxy resin and Nylon SP301, a micron‐sized Nylon 12 powder with a 185°C melting point, composites were prepared at 3%, 9%, and 15% Nylon loading. After curing, these composites underwent controlled heating at 185, 195, and 205°C, with a fusion of 20–100 min. At 185°C, particles initially remain separate, forming slight clumps after 20 min and increasingly sticking together at 60 and 100 min. Shifting to 195°C, particles begin consolidating into a solid mass even after 20 min. The introduction of Nylon decreases composite density compared to pure epoxy, and density changes vary with fusion time, exhibiting complete fusion, partial fusion, and shrinkage‐induced gap formation. Differential scanning calorimetry analysis reveals evolving glass transition temperatures ( T g ) influenced by the fusion process, with longer fusion times yielding higher T g and greater heat capacity.