Here we report a
thermoset shape memory polymer-based syntactic
foam inherently integrated with flame retardancy, good mechanical
properties, excellent shape memory effect, and 3D printability. The
syntactic foam is fabricated by incorporating a high-temperature shape
memory polymer (HTSMP) as the matrix, with 40 vol % hollow glass microspheres
(HGM) K20, K15, and K1 as fillers. Compressive behavior, strain-controlled
programming followed by free recovery, stress recovery, and flame
retardancy of these three syntactic foams were studied. Dynamic mechanical
analysis and thermal characterization validate their high glass transition
temperature (
T
g
= ∼250 °C)
and excellent thermal stability. Our results suggest that the foam
consisting of K20 HGM exhibits high compressive strength (81.8 MPa),
high recovery stress (6.8 MPa), and excellent flame retardancy. Furthermore,
this syntactic foam was used for three-dimensional (3D) printing by
an extruder developed in our lab. Honeycomb, sinusoidal shapes, and
free-standing helical spring were printed for demonstration. This
high-temperature photopolymer-based syntactic foam integrated with
high
T
g
, flame retardancy, high recovery
stress, and 3D printability can be beneficial in different sectors
such as aerospace, construction, oil and gas, automotive, and electronic
industries.