Tailored flexibility in inherently brittle epoxy-based composites through gradient interphase formation with bio-based thermoplastic elastomer grades

This study focuses on tailoring elastic behaviour in an inherently brittle epoxy-based fibre-reinforced composite material formed through a gradient interphase with a bio-based thermoplastic elastomer. The fast-curing epoxy Araldite LY3585/Aradur 3475 was tested with two bio-based Pebax block copolymer grades. First, the interphase was characterised via optical hot-stage microscopy and Raman spectroscopy. The analysis unveiled pronounced diffusion followed by a reaction-induced phase separation, which led to the formation of an interphase with a thickness exceeding 200 μm at the temperatures associated with the curing process. Second, composite laminates were fabricated through a combined process of fused filament fabrication and vacuum infusion, incorporating a flexible domain with variable stiffness properties. The material architecture exhibited brittle-to-ductile behaviour at the micrometre scale, with tailored flexible response under bending and stiff behaviour in tension. Consequently, the study anticipates using multi-scale toughened material structures for more efficient generative design concepts.