Materials Research

Self-Healing Polymer Coating

Thermally-triggered self-healing coating with a bioinspired layered microstructure, recovering 85% of as-cast hardness after damage.

Undergraduate research project Jan – Apr 2025 Independent researcher
85%
hardness recovery after damage
60%
improvement in crack resistance
1
variable to trigger healing: heat
Diagram of the self-healing polymer network: a chemically crosslinked polyurethane phase for mechanical strength, a reversible Diels-Alder system for self-mending, and shape memory closing cracks on heating
The healing mechanism — a crosslinked phase carries load, a reversible Diels–Alder bond re-forms, and shape memory pulls the crack closed under heat.

Overview

Conventional automotive clear coats sustain permanent damage from surface scratching. This project investigated a self-healing alternative capable of restoring mechanical properties after damage without external repair.

The formulation uses a layered microstructure inspired by nacre (mother-of-pearl) — rigid platelets in a compliant matrix — produced via a specialized additive-manufacturing process. Mild, localized heating mobilizes the matrix chemistry and closes microcracks.

Testing across multiple damage-and-heal cycles showed 85% recovery of original hardness and a coating 60% more resistant to crack propagation than the unmodified baseline, at a healing threshold low enough to be practical outside a lab.

Scope of work

  • Formulated and produced the coating using a custom 3D-printing process
  • Designed the damage-and-heal test protocol
  • Ran comparative hardness and fracture-resistance testing
  • Documented results against the unmodified baseline coating

Methods & tools

Materials characterizationAdditive manufacturingMechanical testingData analysis

Questions about this project?

I’m happy to walk through the drawings, data, or decisions behind any case study in an interview.

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