3D Printing Amorphous Polysiloxane Terpolymers via Vat Photopolymerization

Supramolecular Salts for Additive Manufacturing of Polyimides

Recent advances in vat photopolymerization (VP) additive manufacturing of fully aromatic polyimides employed photoreactive high-molecular-weight precursors dissolved at modest loadings (<20 wt %) in organic solvent. These earlier efforts revealed high isotropic shrinkage, approaching 52% on a linear basis while converting to the desired polyimide. To increase the polyimide precursor concentration and decrease shrinkage during VP processing of high-performance polyimides, photoreactive fully aromatic polyimide and thermoplastic polyetherimide (PEI) supramolecular salt precursors now serve as versatile alternatives. Both pyromellitic dianhydride-4,4'-oxydianiline (PMDA-ODA) and 4,4'-(4,4'-isopropylidene-diphenoxy)diphthalic anhydride-meta phenylene diamine (BPADA-mPD) supramolecular dicarboxylate-diammonium salts, termed polysalts, provided prerequisite rheological performance and photoreactivity for VP. Solutions (50 wt %) of both photoactive polysalts exhibited viscosities more than two orders of magnitude lower than previously reported polyimide precursor solutions for VP. In addition, VP of 50 wt % polysalt solutions yielded high resolution, self-supporting organogel structures. During thermal postprocessing to the desired fully aromatic polyimide and PEI, photocrosslinked polysalt organogels exhibited retention of part shape in concert with linear isotropic shrinkage of only 26%, the lowest reported value using organogel strategies for VP of fully aromatic polyimides. Furthermore, the imidized structures exhibited comparable thermal and mechanical properties to analogous polyimides synthesized using classical methodologies for 2D films. The combination of facile synthesis and increased precursor concentrations designates polysalt polyimide precursors as a versatile platform for additive manufacturing of well-defined 3D polyimide structures.

3D Printing of High Viscosity Reinforced Silicone Elastomers

Recent advances in additive manufacturing, specifically direct ink writing (DIW) and ink-jetting, have enabled the production of elastomeric silicone parts with deterministic control over the structure, shape, and mechanical properties. These new technologies offer rapid prototyping advantages and find applications in various fields, including biomedical devices, prosthetics, metamaterials, and soft robotics. Stereolithography (SLA) is a complementary approach with the ability to print with finer features and potentially higher throughput. However, all high-performance silicone elastomers are composites of polysiloxane networks reinforced with particulate filler, and consequently, silicone resins tend to have high viscosities (gel- or paste-like), which complicates or completely inhibits the layer-by-layer recoating process central to most SLA technologies. Herein, the design and build of a digital light projection SLA printer suitable for handling high-viscosity resins is demonstrated. Further, a series of UV-curable silicone resins with thiol-ene crosslinking and reinforced by a combination of fumed silica and MQ resins are also described. The resulting silicone elastomers are shown to have tunable mechanical properties, with 100–350% elongation and ultimate tensile strength from 1 to 2.5 MPa. Three-dimensional printed features of 0.4 mm were achieved, and complexity is demonstrated by octet-truss lattices that display negative stiffness.

Effect of Molecular Weight of Methylphenylsiloxy-Containing Vinyl-Functionalized Terpolysiloxanes on Their UV-Activated Crosslinking by Hydrosilylation and Mechanical Properties of Crosslinked Elastomers

Effects of molecular weight of methylphenyl-containing vinylsiloxy-functionalized terpolysiloxanes on their UV-activated crosslinking by hydrosilylation at room temperature in air, shelf life stability of "all-in-one" pastes prepared from them for additive manufacturing, and mechanical properties of the resulting crosslinked elastomers, are investigated. It is found that while rheology of pastes containing base polymers, trimethylsilylated silica fillers, and thixotropic additives is not significantly affected by the base polymer molecular weight but is dominated by the filler concentration, the pastes based on higher molecular weight polymers exhibit faster crosslinking (corresponding to higher catalyst turnover numbers) and their crosslinked elastomers show transient strain-induced crystallization. The latter appears in networks from terpolymers with degrees of polymerization (DP) of 240 and above (corresponding to about one half of the critical polydimethylsiloxane chain length for entanglement formation of DP = 460), within the temperature range of -80 to -30 °C, characteristic for polydimethylsiloxane melting transition. It is believed that this is the first time an observation of this chain length effect is reported for polysiloxane elastomers and that the properties reported herein can be expected to have major implications on the application potential of these polymers in both additive manufacturing and performance of their elastomers at sub-ambient temperatures.

Fabrication of a Self-Healing, 3D Printable, and Reprocessable Biobased Elastomer

A novel self-healable, fully reprocessable, and inkjet three-dimensional (3D) printable partially biobased elastomer is reported in this work. A long-chain unsaturated diacrylate monomer was first synthesized from canola oil and then cross-linked with a partially oxidized silicon-based copolymer containing free thiol groups and disulfide bonds. The elastomer is fabricated through inkjet 3D printing utilizing the photoinitiated thiol-ene click chemistry and reprocessed by compression molding exploiting the dynamic nature of disulfide bond. Self-healing is enabled by phosphine-catalyzed disulfide metathesis. The elastomer displayed a tensile strength of ∼52 kPa, a breaking strain of ∼24, and ∼86% healing efficiency at 80 °C temperature after 8 h. Moreover, the elastomer showed excellent thermal stability, and the highest thermal degradation temperature was recorded to be ∼524 °C. After reprocessing through compression molding, the elastomer fully recovered its mechanical and thermal properties. These properties of the elastomer yield an ecofriendly alternative of fossil fuel-based elastomers that can find broad applications in soft robotics, flexible wearable devices, strain sensors, health care, and next-generation energy-harvesting and -storage devices.

Rapid High-Resolution Visible Light 3D Printing

Light-driven 3D printing to convert liquid resins into solid objects (i.e., photocuring) has traditionally been dominated by engineering disciplines, yielding the fastest build speeds and highest resolution of any additive manufacturing process. However, the reliance on high-energy UV/violet light limits the materials scope due to degradation and attenuation (e.g., absorption and/or scattering). Chemical innovation to shift the spectrum into more mild and tunable visible wavelengths promises to improve compatibility and expand the repertoire of accessible objects, including those containing biological compounds, nanocomposites, and multimaterial structures. Photochemistry at these longer wavelengths currently suffers from slow reaction times precluding its utility. Herein, novel panchromatic photopolymer resins were developed and applied for the first time to realize rapid high-resolution visible light 3D printing. The combination of electron-deficient and electron-rich coinitiators was critical to overcoming the speed-limited photocuring with visible light. Furthermore, azo-dyes were identified as vital resin components to confine curing to irradiation zones, improving spatial resolution. A unique screening method was used to streamline optimization (e.g., exposure time and azo-dye loading) and correlate resin composition to resolution, cure rate, and mechanical performance. Ultimately, a versatile and general visible-light-based printing method was shown to afford (1) stiff and soft objects with feature sizes <100 μm, (2) build speeds up to 45 mm/h, and (3) mechanical isotropy, rivaling modern UV-based 3D printing technology and providing a foundation from which bio- and composite-printing can emerge.

Moving Towards a Finer Way of Light-Cured Resin-Based Restorative Dental Materials: Recent Advances in Photoinitiating Systems Based on Iodonium Salts

The photoinduced polymerization of monomers is currently an essential tool in various industries. The photopolymerization process plays an increasingly important role in biomedical applications. It is especially used in the production of dental composites. It also exhibits unique properties, such as a short time of polymerization of composites (up to a few seconds), low energy consumption, and spatial resolution (polymerization only in irradiated areas). This paper describes a short overview of the history and classification of different typical monomers and photoinitiating systems such as bimolecular photoinitiator system containing camphorquinone and aromatic amine, 1-phenyl-1,2-propanedione, phosphine derivatives, germanium derivatives, hexaarylbiimidazole derivatives, silane-based derivatives and thioxanthone derivatives used in the production of dental composites with their limitations and disadvantages. Moreover, this article represents the challenges faced when using the latest inventions in the field of dental materials, with a particular focus on photoinitiating systems based on iodonium salts. The beneficial properties of dental composites cured using initiation systems based on iodonium salts have been demonstrated.

A metal-free radical technique for cross-linking of polymethylhydrosiloxane or polymethylvinylsiloxane using AIBN

A new method was developed for the metal-free cross-linking of silicone rubbers. This process uses azobisisobutyronitrile (AIBN) to selectively react with Si-H and vinyl groups as a free-radical initiator for the thermal curing of polymethylhydrosiloxane (PMHS) and polymethylvinylsiloxane (PMVS). The AIBN-initiated curing reaction between the Si-H groups of PMHS generated Si-O-Si and Si-Si cross-links. In contrast, PMVS was cured via the formation of C-C bonds through "methyl-vinyl" and "vinyl-vinyl" mechanisms. Curing reactions were performed at 80-120 °C in air and confirmed by 13C and 29Si solid state NMR analyses and swelling trials.

3D Printing for the Clinic: Examining Contemporary Polymeric Biomaterials and Their Clinical Utility

The advent of additive manufacturing offered the potential to revolutionize clinical medicine, particularly with patient-specific implants across a range of tissue types. However, to date, there are very few examples of polymers being used for additive processes in clinical settings. The state of the art with regards to 3D printable polymeric materials being exploited to produce novel clinically relevant implants is discussed here. We focus on the recent advances in the development of implantable, polymeric medical devices and tissue scaffolds without diverging extensively into bioprinting. By introducing the major 3D printing techniques along with current advancements in biomaterials, we hope to provide insight into how these fields may continue to advance while simultaneously reviewing the ongoing work in the field.