Nanostructure Control in 3D Printed Materials

Covalent Crosslinker-Free Photo-Curing 3D Printing of Liquid Metal Composite Hydrogels Based On SI-photoATRP

Photocurable 3D printing (SLA or DLP) materials have garnered considerable attention due to their remarkable efficiency and precision in manufacturing. However, the presence of covalent crosslinking makes the recycling and reuse of printed materials extremely challenging. Here a novel approach to covalent crosslinker-free photo-curing 3D printing (via DLP) of liquid metal (LM) composite hydrogels is reported, leveraging surface-initiated photoinduced atom radical transfer polymerization (SI-photoATRP). The pre-synthesized PHEA-Br macroinitiators are grafted onto the surfaces of LM nanoparticles (LMNPs) by mechanical sonication, stabilizing the LMNPs within the resin solution while simultaneously generating active sites for SI-photoATRP. During the SI-photoATRP process, polymer chains of sufficient length form hydrogen bonds with multiple LMNPs, effectively transforming the LMNPs into crosslinking points. By integrating the aqueous photoATRP system catalyzed by carbon dots, LM@polymer composite hydrogel with complex structures are successfully established through DLP technology. The versatility of the 3D printed hydrogel is investigated by employing HEA, OEGA480, and AAm as the monomers in resin solution, respectively. Notably, all the LM@polymer composite hydrogels can be degraded in aqueous NaOH solution. Furthermore, LM@polymer-based networks exhibit self-repairing capabilities, serve as underwater adhesives, and conduct electricity. This work offers new insights into designing 3D printing materials and sustainable photocurable technology.

In Situ Fabrication of Quasi-Solid Polymer Electrolytes for Lithium Metal Battery via Photopolymerization-Induced Microphase Separation

The photopolymerization-induced microphase separation (photo-PIMS) process involving a reactive polymer block was implemented to fabricate nanostructured quasi-solid polymer electrolytes (QSPEs) for use in lithium metal batteries (LMBs). This innovative one-pot fabrication enhances interfacial properties in LMBs by enabling in situ nanostructuring of QSPE directly onto the electrodes. This process also allows for customization of QSPE structural dimensions by tweaking the architecture and molar mass of poly[(oligo ethylene glycol) methyl ether methacrylate-co-styrene] (P(OEGMA-co-S)) macromolecular chain transfer agent. Bicontinuous nanoscale domains of soft P(OEGMA-co-S)/propylene carbonate/lithium bis(trifluoromethanesulfonyl)imide (LiTFSI) phase and hard poly[isobornyl acrylate-co-(oligo ethylene glycol)diacrylate] phase furnished the QSPEs with respectively high ionic conductivity (0.34 mS cm-1 at 30 °C) and interesting level of mechanical strength (106-107 Pa at 30 °C). The as-prepared QSPE showed decent electrochemical properties and an electrochemical stability window of about 4.2 V vs Li+/Li. This electrolyte enables the Li||SPE||Li symmetric cell to cycle over 350 h at 0.1 mA cm-2 without evidence of dendrite formation. By means of galvanostatic cycling studies on a prototype lithium metal battery with LiNi0.8Mn0.1Co0.1O2 or LiFePO4 positive electrodes, we further demonstrate that the in situ nanostructured QSPE exhibited better performances than the corresponding stacked battery.

RAFT Polymerization for Advanced Morphological Control: From Individual Polymer Chains to Bulk Materials

Control of the morphology of polymer systems is achieved through reversible-deactivation radical polymerization techniques such as Reversible Addition-Fragmentation chain Transfer (RAFT). Advanced RAFT techniques offer much more than just "living" polymerization - the RAFT toolkit now enables morphological control of polymer systems across many decades of length-scale. Morphological control is explored at the molecular-level in the context of syntheses where individual monomer unit insertion provides sequence-defined polymers (single unit monomer insertion, SUMI). By being able to define polymer architectures, the synthesis of bespoke shapes and sizes of nanostructures becomes possible by leveraging self-assembly (polymerization induced self-assembly, PISA). Finally, it is seen that macroscopic materials can be produced with nanoscale detail, based on phase-separated nanostructures (polymerization induced microphase separation, PIMS) and microscale detail based on 3D-printing technologies. RAFT control of morphology is seen to cross from molecular level to additive manufacturing length-scales, with complete morphological control over all length-scales.

Scalable Macroscopic Engineering from Polymer-Based Nanoscale Building Blocks: Existing Challenges and Emerging Opportunities

Natural materials exhibit exceptional properties due to their hierarchical structures spanning from the nano- to the macroscale. Replicating these intricate spatial arrangements in synthetic materials presents a significant challenge as it requires precise control of nanometric features within large-scale structures. Addressing this challenge depends on developing methods that integrate assembly techniques across multiple length scales to construct multiscale-structured synthetic materials in practical, bulk forms. Polymers and polymer-hybrid nanoparticles, with their tunable composition and structural versatility, are promising candidates for creating hierarchically organized materials. This review highlights advances in scalable techniques for nanoscale organization of polymer-based building blocks within macroscopic structures, including block copolymer self-assembly with additive manufacturing, polymer brush nanoparticles capable of self-assembling into larger, ordered structures, and direct-write colloidal assembly. These techniques offer promising pathways toward the scalable fabrication of materials with emergent properties suited for advanced applications such as bioelectronic interfaces, artificial muscles, and other biomaterials.

Toughening and Imparting Deconstructability to 3D-Printed Glassy Thermosets with "Transferinker" Additives

Thermoset toughness and deconstructability are often opposing features; simultaneously improving both without sacrificing other mechanical properties (e.g., stiffness and tensile strength) is difficult, but, if achieved, could enhance the usage lifetime and end-of-life options for these materials. Here, a strategy that addresses this challenge in the context of photopolymer resins commonly used for 3D printing of glassy, acrylic thermosets is introduced. It is shown that incorporating bis-acrylate "transferinkers," which are cross-linkers capable of undergoing degenerative chain transfer and new strand growth, as additives (5-25 mol%) into homemade or commercially available photopolymer resins leads to photopolymer thermosets with substantially improved tensile toughness and triggered chemical deconstructability with minimal impacts on Young's moduli, tensile strengths, and glass transition temperatures. These properties result from a transferinker-driven topological transition in network structure from the densely cross-linked long, heterogeneous primary strands of traditional photopolymer networks to more uniform, star-like networks with few dangling ends; the latter structure more effectively bear stress yet is also more easily depercolated via solvolysis. Thus, transferinkers represent a simple and effective strategy for improving the mechanical properties of photopolymer thermosets and providing a mechanism for their triggered deconstructability.

Nanostructure design of 3D printed materials through macromolecular architecture

Polymerization-induced microphase separation (PIMS) has been previously combined with 3D printing to develop customized nanostructured materials with a wide range of functional applications. In traditional PIMS, monofunctional, linear macromolecular chain transfer agents (macroCTAs) are used to develop macroCTA-b-P(monomer-stat-crosslinker) networks that self-assemble into unique disordered nanostructures. In this work, we designed a significantly altered network structure by utilizing linear macroCTAs with pendant CTA groups, which provides a novel network upon polymerization (i.e., branched copolymers, [macroCTA-graft-[P(monomer-stat-crosslinker)] n ]-b-P(monomer-stat-crosslinker)). Intriguingly, this method leads to the development of alternative disordered morphologies where the internal nanostructure can be precisely controlled. By systematically varying the number of pendant CTA groups, we demonstrate controlled transitions in macroCTA domain continuity, nanodomain size, and phase interface sharpness. These tunable properties translate to adjustable mechanical and swelling behaviors in the resulting 3D printed objects, ultimately enabling the fabrication of smart 4D materials (swelling-induced actuators and temperature-responsive shape-morphing objects). This research significantly expands the design toolbox for 3D printed PIMS materials, providing increased flexibility in the development of advanced materials with specific nanostructures and functionalities.

Simultaneous Color- and Dose-Controlled Thiol-Ene Resins for Multimodulus 3D Printing with Programmable Interfacial Gradients

Drawing inspiration from nature's own intricate designs, synthetic multimaterial structures have the potential to offer properties and functionality that exceed those of the individual components. However, several contemporary hurdles, from a lack of efficient chemistries to processing constraints, preclude the rapid and precise manufacturing of such materials. Herein, the development of a photocurable resin comprising color-selective initiators is reported, triggering disparate polymerization mechanisms between acrylate and thiol functionality. Exposure of the resin to UV light (365 nm) leads to the formation of a rigid, highly crosslinked network via a radical chain-growth mechanism, while violet light (405 nm) forms a soft, lightly crosslinked network via an anionic step-growth mechanism. The efficient photocurable resin is employed in multicolor digital light processing 3D printing to provide structures with moduli spanning over two orders of magnitude. Furthermore, local intensity (i.e., grayscale) control enables the formation of programmable stiffness gradients with ≈150× change in modulus occurring across sharp (≈200 µm) and shallow (≈9 mm) interfaces, mimetic of the human knee entheses and squid beaks, respectively. This study provides composition-processing-property relationships to inform advanced manufacturing of next-generation multimaterial objects having a myriad of applications from healthcare to education.

Heterogeneous Acrylic Resins with Bicontinuous Nanodomains as Low-Modulus Flexible Adhesives

Adhesives play a critical role in the assembly of electronic devices, particularly as devices become more diverse in form factors. Flexible displays require highly transparent and rapidly recoverable adhesives with a certain stiffness. In this study, novel structured adhesives are developed that incorporate bicontinuous nanodomains to fabricate flexible adhesives with low moduli. This structure is obtained via polymerization-induced microphase separation using a macro chain transfer agent (CTA). Phase separation is characterized using small-angle X-ray scattering, transmission electron microscopy, and dynamic mechanical analysis. By optimizing the length of the macro CTA, an adhesive with both hard and soft nanodomains is produced, resulting in exceptional flexibility (strain recovery = 93%) and minimal modulus (maximum stress/applied strain = 7 kPa), which overperforms traditional adhesives. The optimized adhesive exhibits excellent resilience under extensive strain, as well as strong adhesion and transparency. Furthermore, dynamic folding tests demonstrate the exceptional stability of the adhesive under various temperature and humidity conditions, which is attributed to its unique structure. In summary, the distinct bicontinuous phase structure confers excellent transparency, flexibility, and reduced stiffness to the adhesive, rendering it well-suited for commercial foldable displays and suggesting potential applications in stretchable displays and wearable electronics.

Tailoring of bioactive glass and glass-ceramics properties for in vitro and in vivo response optimization: a review

Bioactive glasses are inorganic biocompatible materials that can find applications in many biomedical fields. The main application is bone and dental tissue engineering. However, some applications in contact with soft tissues are emerging. It is well known that both bulk (such as composition) and surface properties (such as morphology and wettability) of an implanted material influence the response of cells in contact with the implant. This review aims to elucidate and compare the main strategies that are employed to modulate cell behavior in contact with bioactive glasses. The first part of this review is focused on the doping of bioactive glasses with ions and drugs, which can be incorporated into the bioceramic to impart several therapeutic properties, such as osteogenic, proangiogenic, or/and antibacterial ones. The second part of this review is devoted to the chemical functionalization of bioactive glasses using drugs, extra-cellular matrix proteins, vitamins, and polyphenols. In the third and final part, the physical modifications of the surfaces of bioactive glasses are reviewed. Both top-down (removing materials from the surface, for example using laser treatment and etching strategies) and bottom-up (depositing materials on the surface, for example through the deposition of coatings) strategies are discussed.

Digital light processing (DLP) 3D printing of polymer networks comprising virus-like particles

In this work, we introduce a 3D-printable virus-like particle (VLP)-enhanced cross-linked biopolymer system. VLPs displaying surface-available acrylate groups were prepared through aza-Michael addition to serve as resins. The VLP resins were then photopolymerized into a poly(ethylene glycol) diacrylate (PEGDA) network following DLP 3D printing. This approach represents a convergence of disciplines, where the synergistic interaction between virology and additive manufacturing unlocks new frontiers in biotechnology.

Polymerization Induced Microphase Separation of ABC Triblock Copolymers for 3D Printing Nanostructured Materials

Polymerization-induced microphase separation (PIMS) is a versatile technique for producing nanostructured materials. In previous PIMS studies, the predominant approach involved employing homopolymers as macromolecular chain transfer agents (macroCTAs) to mediate the formation of nanostructured materials. In this article, the use of AB diblock copolymers as macroCTAs to design PIMS systems for 3D printing of nanostructured materials is investigated. Specifically, the influence of diblock copolymer composition and block sequence on the resulting nanostructures, and their subsequent impact on bulk properties is systematically investigated. Through careful manipulation of the A/B block ratios, the morphology and size of the nanodomains are successfully controlled. Remarkably, the sequence of A and B blocks significantly affects the microphase separation process, resulting in distinct morphologies. The effect can be attributed to changes in the interaction parameters (χAB, χBC, χAC) between the different block segments. Furthermore, the block sequence and composition exert profound influence on the thermomechanical, tensile, and swelling properties of 3D printed nanostructured materials. By leveraging this knowledge, it becomes possible to design advanced 3D printable materials with tailored properties, opening new avenues for material engineering.

Tuning the Mechanical Properties of 3D-printed Objects by Mixing Chain Transfer Agents in Radical Promoted Cationic RAFT Polymerization

The utilization of (cationic) reversible addition-fragmentation chain transfer (RAFT) polymerization in photoinduced three-dimensional (3D) printing has emerged as a robust technique for fabricating a variety of stimuli-responsive materials. However, methods for precisely adjusting the mechanical properties of these materials remain limited, thereby constraining their broader applicability. In this study, a facile way is introduced to modulate the mechanical properties of 3D printed objects by mixing two chain transfer agents (CTAs) within a radical-promoted cationic RAFT (RPC-RAFT) polymerization-based 3D printing process. Through systematic investigations employing tensile testing and dynamic mechanical analysis (DMA), the influence of CTA concentration and molar ratio between two CTAs on the mechanical behavior of the printed objects are explored. These findings demonstrate that higher concentrations of CTAs or a greater molar ratio of the more active CTA within the mixed CTAs result in decreased Young's modulus and glass transition temperatures of the printed objects. Moreover, the tensile failure strain increased with the increasing CTA content, i.e., the samples became more ductile. This methodology broadens the toolbox available for tailoring the mechanical properties of 3D printed materials.

Robust Gradient Hydrogel-Loaded Nanofiber Fleshy Artificial Skin Via A Coupled Microfluidic Electrospinning-Reactive Coating Strategy

Skin regeneration attracts tremendous interest due to the important role of skin for human protection and beauty. Thus, methods allowing artificial skin to be carried out in a controllable fashion are potentially important for wound healing, which involves an intersection of materials, medicine, biology, and other disciplines. Herein, aiming at a new general methodology for fleshy materials, a new hydrogel-loaded hydrophobic-hydrophilic nanofiber fleshy artificial skin is designed and fabricated. The gradient hydrogel-loaded nanofiber artificial skin integrates both advantages of nanofiber and hydrogel, exhibiting fleshy feature (comparability to real skin in terms of appearance, texture, and function), excellent air permeability, compatibility, and good mechanical and antibacterial property. Interestingly, the efficient transport channels are formed throughout the hydrogel-loaded nanofiber structure, which is beneficial for water absorption and transfer. These advantages enable the establishment of a moist and favorable microenvironment; thus, greatly accelerating wound healing process. This work couples microfluidic electrospinning with reactive coating technique, which is in favor of material design and fabrication with controllable and uniform structures. The hydrogel-loaded nanofiber fleshy artificial skin shows comparability to real skin in terms of beauty, texture, and function, which would definitely provide new opportunities for the further optimization and upgrading of artificial skin.

Semi-crystalline polymers with supramolecular synergistic interactions: from mechanical toughening to dynamic smart materials

Semi-crystalline polymers (SCPs) with anisotropic amorphous and crystalline domains as the basic skeleton are ubiquitous from natural products to synthetic polymers. The combination of chemically incompatible hard and soft phases contributes to unique thermal and mechanical properties. The further introduction of supramolecular interactions as noncovalently interacting crystal phases and soft dynamic crosslinking sites can synergize with covalent polymer chains, thereby enabling effective energy dissipation and dynamic rearrangement in hierarchical superstructures. Therefore, this review will focus on the design principles of SCPs by discussing supramolecular construction strategies and state-of-the-art functional applications from mechanical toughening to sophisticated functions such as dynamic adaptivity, shape memory, ion transport, etc. Current challenges and further opportunities are discussed to provide an overview of possible future directions and potential material applications.

From Unregulated Networks to Designed Microstructures: Introducing Heterogeneity at Different Length Scales in Photopolymers for Additive Manufacturing

Photopolymers have been optimized as protective and decorative coating materials for decades. However, with the rise of additive manufacturing technologies, vat photopolymerization has unlocked the use of photopolymers for three-dimensional objects with new material requirements. Thus, the originally highly cross-linked, amorphous architecture of photopolymers cannot match the expectations for modern materials anymore, revealing the largely unanswered question of how diverse properties can be achieved in photopolymers. Herein, we review how microstructural features in soft matter materials should be designed and implemented to obtain high performance materials. We then translate these findings into chemical design suggestions for enhanced printable photopolymers. Based on this analysis, we have found microstructural heterogenization to be the most powerful tool to tune photopolymer performance. By combining the chemical toolbox for photopolymerization and the analytical toolbox for microstructural characterization, we examine current strategies for physical heterogenization (fillers, inkjet printing) and chemical heterogenization (semicrystalline polymers, block copolymers, interpenetrating networks, photopolymerization induced phase separation) of photopolymers and put them into a material scientific context to develop a roadmap for improving and diversifying photopolymers' performance.

Integrated Three-Dimensional Microdevice with a Modified Surface for Enhanced DNA Separation from Biological Samples

Functional interfaces and devices for rapid adsorption and immobilization of nucleic acids (NAs) are significant for relevant bioengineering applications. Herein, a microdevice with poly(acrylic acid) (PAA) photosensitive resin was integrated by three-dimensional (3D) printing, named DPAA for short. Precise microscale structures and abundant surface carboxyl functional groups were fabricated for fast and high-throughput deoxyribonucleic acid (DNA) separation. Surface modification was then done using polydopamine (PDA) and poly(ethylene glycol) (PEG) to obtain modified poly(acrylic acid) (PAA)-based devices DPDA-PAA and DPEG-PAA rich in amino and hydroxyl groups, respectively. The fabricated device DPAA possessed superior printing accuracy (40-50 μm). Functionalization of amino and hydroxyl was successful, and the modified devices DPDA-PAA and DPEG-PAA maintained a high thermal stability like DPAA. Surface potential analysis and molecular dynamics simulation indicated that the affinity for DNA was in the order of DPDA-PAA > DPEG-PAA > DPAA. Further DNA separation experiments confirmed the high throughput and high selectivity of DNA separation performance, consistent with the predicted affinity results. DPDA-PAA showed relatively the highest DNA extraction yield, while DPEG-PAA was the worst. An acidic binding system is more favorable for DNA separation and recovery. DPDA-PAA showed significantly better DNA extraction performance than DPAA in a weakly acidic environment (pH 5.0-7.0), and the average DNA yield of the first elution was 2.16 times that of DPAA. This work validates the possibility of modification on integrated 3D microdevices to improve their DNA separation efficiency effectively. It also provides a new direction for the rational design and functionalization of bioengineering separators based on nonmagnetic methods. It may pave a new path for the highly efficient polymerase chain reaction diagnosis.

Effect of Macromolecular Structure on Phase Separation Regime in 3D Printed Materials

In this study, the fabrication of 3D-printed polymer materials with controlled phase separation using polymerization induced microphase separation (PIMS) via photoinduced 3D printing is demonstrated. While many parameters affecting the nanostructuration in PIMS processes are extensively investigated, the influence of the chain transfer agent (CTA) end group, i.e., Z-group, of macromolecular chain transfer agent (macroCTA) remains unclear as previous research has exclusively employed trithiocarbonate as the CTA end group. Herein, the effect of macroCTAs containing four different Z-groups on the formation of nanostructure of 3D printed materials is explored. The results show that the different Z-groups lead to distinct network formation and phase separation behaviors between the resins, influencing both the 3D printing process and the resulting material properties. Specifically, less reactive macroCTAs toward acrylic radical addition, such as O-alkyl xanthate and N-alkyl-N-aryl dithiocarbamate, result in translucent and brittle materials with macrophase separation morphology. In contrast, more reactive macroCTAs such as S-alkyl trithiocarbonate and 4-chloro-3,5-dimethylpyrazo dithiocarbamate produce transparent and rigid materials with nano-scale morphology. Findings of this study provide a novel approach to manipulate the nanostructure and properties of 3D printed PIMS materials, which can have important implications for materials science and engineering.

Customized Nanostructured Ceramics via Microphase Separation 3D Printing

To date, the restricted capability to fabricate ceramics with independently tailored nano- and macroscopic features has hindered their implementation in a wide range of crucial technological areas, including aeronautics, defense, and microelectronics. In this study, a novel approach that combines self- and digital assembly to create polymer-derived ceramics with highly controlled structures spanning from the nano- to macroscale is introduced. Polymerization-induced microphase separation of a resin during digital light processing generates materials with nanoscale morphologies, with the distinct phases consisting of either a preceramic precursor or a sacrificial polymer. By precisely controlling the molecular weight of the sacrificial polymer, the domain size of the resulting material phases can be finely tuned. Pyrolysis of the printed objects yields ceramics with complex macroscale geometries and nanoscale porosity, which display excellent thermal and oxidation resistance, and morphology-dependent thermal conduction properties. This method offers a valuable technological platform for the simplified fabrication of nanostructured ceramics with complex shapes.

Polymerization Induced Microphase Separation for the Fabrication of Nanostructured Materials

Polymerization induced microphase separation (PIMS) is a strategy used to develop unique nanostructures with highly useful morphologies through the microphase separation of emergent block copolymers during polymerization. In this process, nanostructures are formed with at least two chemically independent domains, where at least one domain is composed of a robust crosslinked polymer. Crucially, this synthetically simple method is readily used to develop nanostructured materials with the highly coveted co-continuous morphology, which can also be converted into mesoporous materials by selective etching of one domain. As PIMS exploits a block copolymer microphase separation mechanism, the size of each domain can be tightly controlled by modifying the size of block copolymer precursors, thus providing unparalleled control over nanostructure and resultant mesopore sizes. Since its inception 11 years ago, PIMS has been used to develop a vast inventory of advanced materials for an extensive range of applications including biomedical devices, ion exchange membranes, lithium-ion batteries, catalysis, 3D printing, and fluorescence-based sensors, among many others. In this review, we provide a comprehensive overview of the PIMS process, summarize latest developments in PIMS chemistry, and discuss its utility in a wide variety of relevant applications.

3D Printing Hierarchically Nano-Ordered Structures

Natural materials are composed of a limited number of molecular building blocks and their exceptional properties are governed by their hierarchical structure. However, this level of precision is unattainable with current state-of-the-art materials for 3D printing. Herein, new self-assembled printable materials based on block copolymers (BCPs) enabling precise control of the nanostructure in 3D are presented. In particular, well-defined BCPs consisting of poly(styrene) (PS) and a polymethacrylate-based copolymer decorated with printable units are selected as suitable self-assembled materials and synthesized using controlled radical polymerization. The synthesized library of BCPs are utilized as printable formulations for the fabrication of complex 3D microstructures using two-photon laser printing. By fine-tuning the BCP composition and solvent in the formulations, the fabrication of precise 3D nano-ordered structures is demonstrated for the first time. A key point of this work is the achievement of controlled nano-order within the entire 3D structures. Thus, imaging of the cross-sections of the 3D printed samples is performed, enabling the visualization also from the inside. The presented versatile approach is expected to create new avenues for the precise design of functional polymer materials suitable for high-resolution 3D printing exhibiting tailor-made nanostructures.

On-Demand Tunability of Microphase Separation Structure of 3D Printing Material by Reversible Addition/Fragmentation Chain Transfer Polymerization

Controlling the phase-separated structure of polymer alloys is a promising method for tailoring the properties of polymers. However, controlling the morphology of phase-separated structures is challenging. Recently, phase-separated structures have been fabricated via 3D printing; however, only a few methods that enable on-demand control of phase separation have been reported. In this study, laser-scanning stereolithography, a vat photopolymerization method, is used to form a phase-separated structure via polymerization-induced microphase separation by varying the scanning speed and using macro-reversible addition/fragmentation chain transfer (macro-RAFT) agents with different average molar masses, along with multiarmed macro-RAFT agents; such structures were used to fabricate 3D-printed parts. Various phase-separated morphologies including sea-island and reverse sea-island were achieved by controlling the laser scanning speed and RAFT type. Heterogeneous structures with different material properties were also achieved by simply changing the laser scanning speed. As the deformation due to shrinkage in the process of cleaning 3D-printed parts depends on the laser scanning speed, shape correction was introduced to suppress the effect of shrinkage and obtain the desired shape.

Advanced supramolecular design for direct ink writing of soft materials

The exciting advancements in 3D-printing of soft materials are changing the landscape of materials development and fabrication. Among various 3D-printers that are designed for soft materials fabrication, the direct ink writing (DIW) system is particularly attractive for chemists and materials scientists due to the mild fabrication conditions, compatibility with a wide range of organic and inorganic materials, and the ease of multi-materials 3D-printing. Inks for DIW need to possess suitable viscoelastic properties to allow for smooth extrusion and be self-supportive after printing, but molecularly facilitating 3D printability to functional materials remains nontrivial. While supramolecular binding motifs have been increasingly used for 3D-printing, these inks are largely optimized empirically for DIW. Hence, this review aims to establish a clear connection between the molecular understanding of the supramolecularly bound motifs and their viscoelastic properties at bulk. Herein, extrudable (but not self-supportive) and 3D-printable (self-supportive) polymeric materials that utilize noncovalent interactions, including hydrogen bonding, host-guest inclusion, metal-ligand coordination, micro-crystallization, and van der Waals interaction, have been discussed in detail. In particular, the rheological distinctions between extrudable and 3D-printable inks have been discussed from a supramolecular design perspective. Examples shown in this review also highlight the exciting macroscale functions amplified from the molecular design. Challenges associated with the hierarchical control and characterization of supramolecularly designed DIW inks are also outlined. The perspective of utilizing supramolecular binding motifs in soft materials DIW printing has been discussed. This review serves to connect researchers across disciplines to develop innovative solutions that connect top-down 3D-printing and bottom-up supramolecular design to accelerate the development of 3D-print soft materials for a sustainable future.

3D Printed Solid Polymer Electrolytes with Bicontinuous Nanoscopic Domains for Ionic Liquid Conduction and Energy Storage

Solid polymer electrolytes (SPEs) offer several advantages compared to their liquid counterparts, and much research has focused on developing SPEs with enhanced mechanical properties while maintaining high ionic conductivities. The recently developed polymerization-induced microphase separation (PIMS) technique offers a straightforward pathway to fabricate bicontinuous nanostructured materials in which the mechanical properties and conductivity can be independently tuned. In this work SPEs with tunable mechanical properties and conductivities are prepared via digital light processing 3D printing, exploiting the PIMS process to achieve nanostructured ion-conducting materials for energy storage applications. A rigid crosslinked poly(isobornyl acrylate-stat-trimethylpropane triacrylate) scaffold provided materials with room temperature shear modulus above 400 MPa, while soft poly(oligoethylene glycol methyl ether acrylate) domains containing the ionic liquid 1-butyl-3-methylimidazolium bis-(trifluoromethyl sulfonyl)imide endowed the material with ionic conductivity up to 1.2 mS cm^-1 at 30 °C. These features make the 3D-printed SPE very competitive for applications in all solid energy storage devices, including supercapacitors.

Fast Living 3D Printing via Free Radical Promoted Cationic RAFT Polymerization

The application of reversible deactivation radical polymerization techniques in 3D printing is emerging as a powerful method to build "living" polymer networks, which can be easily postmodified with various functionalities. However, the building speed of these systems is still limited compared to commercial systems. Herein, a digital light processing (DLP)-based 3D printing system via photoinduced free radical-promoted cationic reversible addition-fragmentation chain transfer polymerization of vinyl ethers, which can build "living" objects by a commercial DLP 3D printer at a relatively fast building speed (12.99 cm h^-1 ), is reported. The polymerization behavior and printing conditions are studied in detail. The livingness of the printed objects is demonstrated by spatially controlled postmodification with a fluorescent monomer.

Poly(ethylene glycol)-Norbornene as a Photoclick Bioink for Digital Light Processing 3D Bioprinting

Digital light processing (DLP) bioprinting is an emerging technology for three-dimensional bioprinting (3DBP) owing to its high printing fidelity, fast fabrication speed, and higher printing resolution. Low-viscosity bioinks such as poly(ethylene glycol) diacrylate (PEGDA) are commonly used for DLP-based bioprinting. However, the cross-linking of PEGDA proceeds via chain-growth photopolymerization that displays significant heterogeneity in cross-linking density. In contrast, step-growth thiol-norbornene photopolymerization is not oxygen inhibited and produces hydrogels with an ideal network structure. The high cytocompatibility and rapid gelation of thiol-norbornene photopolymerization have lent itself to the cross-linking of cell-laden hydrogels but have not been extensively used for DLP bioprinting. In this study, we explored eight-arm PEG-norbornene (PEG8NB) as a bioink/resin for visible light-initiated DLP-based 3DBP. The PEG8NB-based DLP resin showed high printing fidelity and cytocompatibility even without the use of any bioactive motifs and high initial stiffness. In addition, we demonstrated the versatility of the PEGNB resin by printing solid structures as cell culture devices, hollow channels for endothelialization, and microwells for generating cell spheroids. This work not only expands the selection of bioinks for DLP-based 3DBP but also provides a platform for dynamic modification of the bioprinted constructs.

3D Printing Nanostructured Solid Polymer Electrolytes with High Modulus and Conductivity

The development of advanced solid-state energy-storage devices is contingent upon finding new ways to produce and manufacture scalable, high-modulus solid-state electrolytes that can simultaneously provide high ionic conductivity and robust mechanical integrity. In this work, an efficient one-step process to manufacture solid polymer electrolytes composed of nanoscale ion-conducting channels embedded in a rigid crosslinked polymer matrix via Digital Light Processing 3D printing is reported. A visible-light-mediated polymerization-induced microphase-separation approach is utilized, which produces materials with two chemically independent nanoscale domains with highly tunable nanoarchitectures. By producing materials containing a poly(ethylene oxide) domain swelled with an ionic liquid, robust solid polymer electrolytes with outstanding room-temperature (22 °C) shear modulus (G' > 10⁸ Pa) and ionic conductivities up to σ = 3 × 10^-4 S cm^-1 are achieved. The nanostructured 3D-printed electrolytes are fabricated into a custom geometry and employed in a symmetric carbon supercapacitor, demonstrating the scalability of the fabrication and the functionality of the electrolyte. Critically, these high-performance materials are manufactured on demand using inexpensive and commercially available 3D printers, which allows the facile modular design of solid polymer electrolytes with custom geometries.

Nano- to macro-scale control of 3D printed materials via polymerization induced microphase separation

Although 3D printing allows the macroscopic structure of objects to be easily controlled, controlling the nanostructure of 3D printed materials has rarely been reported. Herein, we report an efficient and versatile process for fabricating 3D printed materials with controlled nanoscale structural features. This approach uses resins containing macromolecular chain transfer agents (macroCTAs) which microphase separate during the photoinduced 3D printing process to form nanostructured materials. By varying the chain length of the macroCTA, we demonstrate a high level of control over the microphase separation behavior, resulting in materials with controllable nanoscale sizes and morphologies. Importantly, the bulk mechanical properties of 3D printed objects are correlated with their morphologies; transitioning from discrete globular to interpenetrating domains results in a marked improvement in mechanical performance, which is ascribed to the increased interfacial interaction between soft and hard domains. Overall, the findings of this work enable the simplified production of materials with tightly controllable nanostructures for broad potential applications.

Ultrafast Visible-Light-Induced ATRP in Aqueous Media with Carbon Quantum Dots as the Catalyst and Its Application for 3D Printing

Photoinduced atom transfer radical polymerization (ATRP) has been proved to be a versatile technique for polymer network formation. However, the slow polymerization rates of typical ATRP limited its application in the field of additive manufacturing (3D printing). In this work, we introduced carbon quantum dots (CQDs) for the first time to the ATRP in aqueous media and developed an ultrafast visible-light-induced polymerization system. After optimization, the polymerization could achieve a high monomer conversion (>90%) within 1 min, and the polydispersity index (PDI) of the polymer was lower than 1.25. This system was then applied as the first example of ATRP for the 3D printing of hydrogel through digital light processing (DLP), and the printed object exhibited good dimensional accuracy. Additionally, the excellent and stable optical properties of CQDs also provided interesting photoluminescence capabilities to the printed objects. We deduce this ATRP mediated 3D printing process would provide a new platform for the preparation of functional and stimuli-responsive hydrogel materials.

Recent Trends in Advanced Photoinitiators for Vat Photopolymerization 3D Printing

3D printing has revolutionized the way of manufacturing with a huge impact on various fields, in particular biomedicine. Vat photopolymerization-based 3D printing techniques such as stereolithography (SLA) and digital light processing (DLP) attracted considerable attention owing to their superior print resolution, relatively high speed, low cost and flexibility in resin material design. As one key element of the SLA/DLP resin, photoinitiators or photoinitiating systems have experienced significant development in recent years, in parallel with the exploration of 3D printing (macro)monomers. The design of new photoinitiating systems can not only offer faster 3D printing speed and enable low-energy visible light fabrication, but also can bring new functions to the 3D printed products and even generate new printing methods in combination with advanced optics. This review evaluates recent trends in the development and application of advanced photoinitiators and photoinitiating systems for vat photopolymerization 3D printing, with a wide range of small molecules, polymers and nanoassemblies involved. Personal perspectives on the current limitations and future directions are eventually provided. This article is protected by copyright. All rights reserved.

Tuning Catalyst-Free Photocontrolled Polymerization by Substitution: A Quantitative and Qualitative Interpretation

Catalyst-free photocontrolled reversible addition-fragmentation chain transfer (RAFT) polymerization avoids the side effects of photocatalysts but has the accompanying slow kinetics, thereby warranting more efficient photolysis and faster chain transfer. To understand the underlying mechanisms, both quantitative and qualitative interpretations are needed. Such a goal can be achieved by the iCAS (imposed automatic selection and localization of complete active spaces) approach [J. Chem. Theory Comput. 2021, 17, 4846], which maintains the same CAS and meanwhile provides localized orbitals along the whole reaction. Taking dithiobenzoate as a representative of RAFT agents, it is found here that electron-donating substitution (by methoxy) clearly outperforms both electron-standing (by methyl) and electron-withdrawing (by cyano) substitutions in facilitating photo-RAFT polymerization, by narrowing the gap between the π* and σ* orbitals, so as to facilitate the π* → σ* charge transfer dominating both the photolysis and chain transfer processes. Such findings are of general values.