High-intensity and low-divergence laser beams can cause damage to the human eye, sensors, and photoreceptors. In harsh environments, optical sensors can be damaged by pulsed laser radiation if exposed beyond their capacity. To protect against such threats, passive optical limiting devices are used. These devices are self-activated systems with a low activation threshold, neutral color, and low response time. Methacrylate-based thermosets were synthesized via radical polymerization using a reactive oligomer and a monomer. Two processes were investigated in this study: thermal polymerization, which is solvent-free, allows to collect directly the sample and can take several hours, and 3D printing, which uses photopolymerization to produce samples. This is an innovative method that allows for the production of multiple samples in under 10 minutes. Furthermore, a non-linear dye has been incorporated into the methacrylate matrix. In this study, optical filters with a methacrylate matrix and a 0.01 wt% loading dye are prepared by bulk polymerization and photopolymerization processes. The samples are then characterized to demonstrate the same chemical composition and thermal behavior. Finally, the optical limiting properties of the thermoset polymers at a wavelength of 1064 nm are investigated. The two processes are compared to determine their relevance.
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