Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications

Microplastic pollution in Pearl River networks: Characteristic, potential sources, and migration pathways

Microplastic (MP) pollution has become a global environmental problem with profound impacts on aquatic ecosystems. Although the topic of MPs has attracted high attention, the sources, transport pathway, and removal of MPs in river networks is still unclear. Here, we conducted a field survey across the Pearl River Basin (PRB) (> 4.5 × 105 km2) and collected the water samples to characterize the spatial distribution of MPs using a Laser Direct Infrared (LDIR) chemical imaging system. The MPs were detected in all samples with an average abundance of 1092.86 items/L, in which polyamide (PA), polyurethane (PU), and polyvinyl chloride (PVC) are the main polymer types. Population and surface runoff were identified as major factors influencing the concentrations of MPs. The Partial Least Squares Structural Equation Modeling (PLS-PM) analysis revealed that precipitation-induced surface runoff is a major pathway for MPs transferring from terrestrial environment to river networks. River hydraulic dynamics were found to have considerable influence on the selective removal of MPs from water column in the river channel. The smooth state (Froude number, Fr <0.23) promotes while the rough state (Fr > 0.23) inhibits the deposition of MPs from water column to sediments. In particular, the smooth state facilitates the deposition of large-sized and high-density MPs from the water column to sediments. The deposition processes in river channel cause considerable fractionation of polymer types and size of riverine MPs. This study provides the first-hand MP pollution status in the networks of the PRB and provide insights into sources, spatial distribution characteristics, and transmission mechanism of MPs in river networks, which would provide theoretical bases and experimental reference for river water quality management and risk control of MPs for governor, stakeholders, and policy makers.

Rapid Gelation of Dicyclopentadiene Resins for Additive Manufacturing of Thermoset Polymers

Thermoset resins of dicyclopentadiene were viscosity-modified to achieve the rheology necessary for Direct Ink Writing, with the deposited ink solidified on-the-fly by frontal polymerization. This rapid modification strategy incorporated the ruthenium-based Grubbs' third-generation catalyst and a ligand exchange reaction to decrease the gelation time for resins to under 10 min, an order of magnitude less than existing strategies. The gelled resins are rheologically stable and retain their reactivity for over 500 days. Viscosity modification enables 3D-printing of these resins, producing polymers with thermomechanical properties that match or surpass those from resins gelled more slowly. Replacing the solvent eliminates reduction in glass transition temperature from plasticization while maintaining extended resin pot life.

Frontal polymerization in thin layers: Hydrodynamic effects and asymptotic dynamics

Buoyancy-driven convection currents arise from temperature gradients in thermal frontal polymerization (FP) when the spatially localized polymerization reaction travels perpendicularly to the gravity field. We propose a theoretical study of the system dynamics under adiabatic conditions. The polymer and the reactant mixture are considered to be in the same liquid phase, but the viscosity can increase with the degree of polymerization. We find that the reaction zone propagates as a hot spot-like pattern with a broken symmetry in both the vertical and horizontal directions. Furthermore, the system can reach an asymptotic dynamics characterized by a front with a steady shape that propagates at constant speed with a steady vortex surrounding it. As the strength of the vortex is increased, either by decreasing the reactants' viscosity or by increasing the layer's thickness, we observe a transition between (i) a passive regime predicted by pure reaction-diffusion and hydrodynamic models and (ii) an active chemo-hydrodynamic regime where such models separately break down. In the active regime (ii), the front speed decreases as convection intensifies. By means of a scaling analysis, we explain how hydrodynamic currents might lower the velocity of a polymerization wave. As the viscosity of the polymer is enlarged, the flow is shifted ahead of the reaction zone and becomes more symmetrical with respect to the middle of the system, as recently observed in solid-liquid FP experiments [Y. Gao et al., Phys. Rev. Lett. 130, 028101 (2023) and Y. Gao et al., Int. J. Heat Mass Transf. 240, 126622 (2025)].

Frontal Polymerization of Epoxy Resins: Kinetic Modeling, Rate Regulation and Curing Process Simulation for Space Manufacturing Applications

Frontal polymerization (FP) technology has attracted significant attention as an efficient, low-energy curing method for thermosetting resins. By enabling self-sustaining polymerization reactions, FP significantly reduces curing time and minimizes external energy dependence, making it ideal for in-orbit manufacturing applications. In contrast to traditional curing methods, which are limited by high energy consumption and low efficiency, FP offers a more efficient and flexible alternative. Nonetheless, the FP process is sensitive to material composition, processing and environmental factors, requiring systematic studies to enhance performance. This work focuses on reaction mechanisms, curing kinetics and processing factors of a self-developed FP epoxy resin system. The revealed curing mechanism and kinetics reveals a high initiation energy barrier and rapid curing characteristics, showing appropriate reaction inertness before initiation and stable reaction without continuous external energy input. The influences of initiator concentration and epoxy resin type on polymerization rate and the properties of cured resin were examined. Additionally, a curing simulation method validated by the experiment were employed to analyze the effects of mold material, resin cross-sectional area, initial temperature and environmental conditions on polymerization behavior. The results provide valuable insights for optimizing FP, advancing the understanding of the curing process and improving resin performance in space-based applications.

Circular Workflow for Thermosets: Activatable Repeat Unit Design for Regenerative Frontal Polymerization

Thermoset materials are indispensable in high-performance applications due to their exceptional mechanical properties, chemical resistance, and thermal stability. However, their cross-linked structure poses significant challenges for sustainable manufacturing and end-of-life reprocessing. Herein, we present a novel approach to regenerate high-performance polydicyclopentadiene (pDCPD) thermoset materials through a one-pot deconstruction-reactivation strategy enabled by an "activatable repeat unit", norbornene-furan (NBF). The pendant furyl ring of NBF remains intact during the initial curing reaction via frontal ring-opening metathesis polymerization (FROMP) and retains its reactivity for subsequent Diels-Alder cycloaddition with the in situ generated benzyne. Deconstruction-reactivation proceeds in one pot to effectively recover the activated oligomers for further FROMP curing, thereby completing the circular workflow. The regenerated materials demonstrate retention of key properties, including glass transition temperature (Tg), stiffness, and yield strength, while maintaining their deconstruction capability. This strategy provides a sustainable framework for thermoset material design and regeneration, addressing critical challenges in material circularity and environmental impact.

Controlling the Spatiotemporal Self-Organization of Stimuli-Responsive Nanocrystals under Out-of-Equilibrium Conditions

Self-organization under out-of-equilibrium conditions is ubiquitous in natural systems for the generation of hierarchical solid-state patterns of complex structures with intricate properties. Efforts in applying this strategy to synthetic materials that mimic biological function have resulted in remarkable demonstrations of programmable self-healing and adaptive materials. However, the extension of these efforts to multifunctional stimuli-responsive solid-state materials across defined spatial distributions remains an unrealized technological opportunity. This paper describes the use of a nonequilibrium reaction-diffusion process to achieve the synthesis of a multifunctional stimuli-responsive electrically conductive metal-organic framework (cMOF) in a gelled medium with control over particle size and spatial periodicity on a macroscopic scale. Upon integration into chemiresistive devices, the resulting cMOF particles exhibit a size-dependent response toward hydrogen sulfide gas, as determined by their distinct surface-to-volume ratio, porosity, unique synthesis methodology, and unusual microcrystallite morphology compared to their counterparts obtained through bulk solution phase synthesis. Taken altogether, these achievements pave the way toward gaining access to functional nanomaterials with well-defined chemical composition, dimensions, and precisely tailored functions using far-from-equilibrium approaches.

Aliphatic-acid coating and nano chitosan nucleator synergistically regulate the performance of PMMA "bone-Locking" foam dressing used for emergency fixation of clavicle fracture

Clavicle emergency fixation can prevent fractured end from piercing heart and lung organs, which is crucial for wounded life. Clavicle with complex structure, great individual differences, and adjacent to important organs, which places high-requirements on performance of fixation materials. Developing advanced clavicle fixation material is a prominent hot-topic in the field of emergency-engineering. We prepared a Polymethyl-methacrylate (PMMA) "bone-Locking" foam dressing via novel polymer foaming process. Innovatively used aliphatic-acid and bio-polar macromolecule nanoparticles to adjust structure in non-traditional self-curing polymer melts to achieve high-performance. Stearic acid coating was prepared on the surface of foaming agent can delay nucleation period, increasing the initial Polymer-Bubble interface viscosity and effectively retard nuclei growth and escape. Nano-chitosan was compounded synchronously to induce in-situ nucleation and construct polar hydrogen bonds between chains, improve the crystallinity of PMMA matrix, reduce the relaxation ability of PMMA molecular chains and increase the interface viscosity again to inhibit nuclei growth and escape, realizing spontaneous coordination between viscosity and the bubble holes formation process. Obtained high-performance foam with uniform and regular bubble holes structure eventually. More, Dynamic Dual-Variable Field Bubble-Growth Dynamics was proposed, revealing the Bubble-Growth behavior synergistic driven by Viscosity and Temperature theoretically, providing reference for improving theory in polymer foaming field. Prepared foam dressing can be directly and softly coated on clavicle and spontaneously conform to the contour of clavicle with remarkable precision, then quickly (3.5 min) curing into a lightweight (0.57 g/cm3), high-strength (40.5 MPa), breathable (224.73 mm/s) "Armor", showing great application value in wound emergency engineering. The developed foaming method and theory provide technical and theoretical value for polymer foaming system. The foam dressing provides a promising new scheme for fixing various wound sites and ensuring the life safety of the wounded at the emergency scene.

MXene Hydrogels for Soft Multifunctional Sensing: A Synthesis-Centric Review

Intelligent wearable sensors based on MXenes hydrogels are rapidly advancing the frontier of personalized healthcare management. MXenes, a new class of transition metal carbon/nitride synthesized only a decade ago, have proved to be a promising candidate for soft sensors, advanced human-machine interfaces, and biomimicking systems due to their controllable and high electrical conductivity, as well as their unique mechanical properties as derived from their atomistically thin layered structure. In addition, MXenes' biocompatibility, hydrophilicity, and antifouling properties render them particularly suitable to synergize with hydrogels into a composite for mechanoelectrical functions. Nonetheless, while the use of MXene as a multifunctional surface or an electrical current collector such as an energy device electrode is prevalent, its incorporation into a gel system for the purpose of sensing is vastly less understood and formalized. This review provides a systematic exposition to the synthesis, property, and application of MXene hydrogels for intelligent wearable sensors. Specific challenges and opportunities on the synthesis of MXene hydrogels and their adoption in practical applications are explicitly analyzed and discussed to facilitate cross gemination across disciplines to advance the potential of MXene multifunctional sensing hydrogels.

State-of-the-Art Synthesis of Porous Polymer Materials and Their Several Fantastic Biomedical Applications: a Review

Porous polymers, including hydrogels, covalent organic frameworks (COFs), and hyper crosslinked polymers (HCPs), have become essential in biomedical research for their tunable pore architectures, large surface areas, and functional versatility. This review provides a comprehensive overview of their classification and updated synthesis mechanisms, such as 3D printing, electrospinning, and molecular imprinting. Their pivotal roles in drug delivery, tissue engineering, wound healing, and photodynamic/photothermal therapies, focusing on how pore size, distribution, and architecture impact drug release, cellular interactions, and therapeutic outcomes, are explored. Key challenges, including biocompatibility, mechanical strength, controlled degradation, and scalability, are critically assessed alongside emerging strategies to enhance clinical potential. Finally, recent challenges and future perspectives, emphasizing the broader biomedical applications of porous polymers, are addressed. This work provides valuable insights for advancing next-generation biomedical innovations through these materials.

Revivable self-assembled supramolecular biomass fibrous framework for efficient microplastic removal

Microplastic remediation in aquatic bodies is essential for the entire ecosystem, but is challenging to achieve with a universal and efficient strategy. Here, we developed a sustainable and environmentally adaptable adsorbent through supramolecular self-assembly of chitin and cellulose. This biomass fibrous framework (Ct-Cel) showcases an excellent adsorption performance for polystyrene, polymethyl methacrylate, polypropylene, and polyethylene terephthalate. The affinity for diverse microplastics is attributed to the transformation of multiple intermolecular interactions between different microplastics and Ct-Cel. Meanwhile, the strong resistance of Ct-Cel to multiple pollutants in water enables an enhanced adsorption when coexisting with microorganisms and Pb2+. Moreover, Ct-Cel can remove 98.0 to 99.9% of microplastics in four types of real water and maintains a high removal efficiency of up to 95.1 to 98.1% after five adsorption cycles. This work may open up prospects for functional biomass materials for cost-efficient remediation of microplastics in complex aquatic environments.

Photochemical Reaction Front Propagation and Control in Molecular Crystals

4-Fluoro-9-anthracenecarboxylic acid (4F-9AC) undergoes a reversible [4 + 4] photodimerization reaction that can generate bending and twisting in microcrystals. Larger crystals resist photomechanical deformation, permitting direct visualization of the [4 + 4] photodimerization reaction dynamics under a variety of conditions. Both birefringence and fluorescence imaging show that the photodimerization reaction starts preferentially at a crystal edge and then sweeps across the crystal as a propagating reaction front. To explain these results, a theory is developed that postulates an exponentially decaying mechanical reaction field that extends from product domain into reactant domains to catalyze the photochemical reaction. Analyzing the data with this theory, we estimate a reaction field penetration distance of ∼20 nm for the 4F-9AC crystal. The propagation velocity can be controlled by varying the excitation intensity or by embedding amorphous barrier regions into the crystal using electron beam lithography. These barriers can channel the reaction flow to select areas of the crystal while other regions remain unreacted.

Residual Strain Development in Rapid Frontally Curing Polymers

Frontal polymerization (FP) has emerged as a rapid and energy-efficient process for fabricating thermoset polymers and composites. In this process, a self-propagating reaction front cures the polymer rapidly by the exothermic heat of polymerization reaction instead of an external heat source. Design for FP-based manufacturing in commercial applications requires more comprehensive characterization and prediction of material evolution and residual deformation throughout the process. Here, we report experimental and numerical studies in response to this need. The experimental study focuses on measuring the temperature and cure-dependent properties of mono/poly dicyclopentadiene to capture the strain evolution during the frontal polymerization process. The experimentally measured elastic moduli, Poisson's ratios, and coefficients of thermal expansion and chemical shrinkage show strong dependence on the degree of cure. Based on the experimental output, a coupled thermo-chemo-mechanical model has been developed to capture the measured residual strains. The chemical shrinkage is closely related to the curing rate, leading to strong localization of residual strains in accelerated reaction regions, especially where two fronts merge. Preheating of the monomer (or gel) at the fronts merging area is suggested as an effective method to mitigate residual deformations.

Self-Activated Energy Release Cascade from Anthracene-Based Solid-State Molecular Solar Thermal Energy Storage Systems

We introduce donor-acceptor substituted anthracenes as effective molecular solar thermal energy storage compounds that operate exclusively in the solid state. The donor-acceptor anthracenes undergo visible light-induced [4+4] cycloaddition reaction, producing metastable cycloadducts, dianthracenes with quaternary carbons, and storing photon energy. The triggered cycloreversion of dianthracenes to anthracenes discharges the stored energy as heat in the order of 100 kJ/mol (200 J/g). The series of compounds displays remarkable self-heating, or cascading heat release, upon the initial triggering. Such self-activated energy release is enabled by the large energy storage in dianthracenes, low activation energy for their thermal reversion, and effective heat transfer to unreacted molecules in the solid state. This process mirroring the self-ignition of fossil fuels opens up opportunities to use dianthracenes as effective and renewable solid-state fuels that can release energy rapidly and completely upon initial activation.

Bubble-Free Frontal Polymerization of Acrylates via Redox-Initiated Free Radical Polymerization

Thermal frontal polymerization (FP) of acrylate monomers mixed with conventional peroxide initiators leads to significant bubble formation at the polymerizing front, limiting their practical applications. Redox initiators present a promising alternative to peroxide initiators, as they prevent the formation of gaseous byproducts during initiator decomposition and lower the front temperature, thereby enabling bubble-free FP. In this study, we investigate the FP of acrylate monomers of varying functionalities, including methyl methacrylate (MMA), 1,6-hexanediol diacrylate (HDDA), and trimethylolpropane triacrylate (TMPTA), using N,N-dimethylaniline/benzoyl peroxide (DMA/BPO) redox couple at room temperature and compare their front behavior, pot life, and bubble formation with those of same resin systems mixed with a conventional peroxide initiator, Luperox 231. The use of redox couples in FP of acrylates shows promise for rapid, energy-efficient manufacturing of polyacrylates and can enable new applications such as 3D printing and composite manufacturing.

Ultra-Fast Preparation of High-Strength Polymer Concrete via Frontal Polymerization at Room Temperature

Concrete, in particular application scenarios, such as crack repair, disaster rescue and relief, and 3D printing, needs to be cured quickly. In this work, a novel synthesis strategy, UV-initiated frontal polymerization (FP), for fast preparation of high-strength polymer concrete at room temperature is proposed, and the whole fabrication progress within several minutes, in which coarse aggregates and a small amount of short carbon fibers (CF) are used to enhance mechanical properties and heat conduction and reduce the amounts of chemical adhesives. SEM, DSC, MIP, Ultra depth of field microscope, and Rheometer are employed to characterize the properties of chemical adhesives, polymer concrete, and polymerization process. In addition, the finite element method is used to investigate the internal temperature field status of the FP process. The results indicate that the compressive and flexural strengths of the polymer concrete with 1.0 wt%-1 mm-CF-50 vol.%-quartz sand exceeded 70 and 20 MPa, respectively, in which the average self-propagation velocity reached 58 mm min-1. The investigation provides a promising approach for the rapid construction of structural facilities, emergency repair after disasters, 3D printing concrete, etc.

Controlled patterning of crystalline domains by frontal polymerization

Materials with hierarchical architectures that combine soft and hard material domains with coalesced interfaces possess superior properties compared with their homogeneous counterparts1-4. These architectures in synthetic materials have been achieved through deterministic manufacturing strategies such as 3D printing, which require an a priori design and active intervention throughout the process to achieve architectures spanning multiple length scales5-9. Here we harness frontal polymerization spin mode dynamics to autonomously fabricate patterned crystalline domains in poly(cyclooctadiene) with multiscale organization. This rapid, dissipative processing method leads to the formation of amorphous and semi-crystalline domains emerging from the internal interfaces generated between the solid polymer and the propagating cure front. The size, spacing and arrangement of the domains are controlled by the interplay between the reaction kinetics, thermochemistry and boundary conditions. Small perturbations in the fabrication conditions reproducibly lead to remarkable changes in the patterned microstructure and the resulting strength, elastic modulus and toughness of the polymer. This ability to control mechanical properties and performance solely through the initial conditions and the mode of front propagation represents a marked advancement in the design and manufacturing of advanced multiscale materials.

Reactive Processing of Furan-Based Monomers via Frontal Ring-Opening Metathesis Polymerization for High Performance Materials

Frontal ring-opening metathesis polymerization (FROMP) presents an energy-efficient approach to produce high-performance polymers, typically utilizing norbornene derivatives from Diels-Alder reactions. This study broadens the monomer repertoire for FROMP, incorporating the cycloaddition product of biosourced furan compounds and benzyne, namely 1,4-dihydro-1,4-epoxynaphthalene (HEN) derivatives. A computational screening of Diels-Alder products is conducted, selecting products with resistance to retro-Diels-Alder but also sufficient ring strain to facilitate FROMP. The experiments reveal that varying substituents both modulate the FROMP kinetics and enable the creation of thermoplastic materials characterized by different thermomechanical properties. Moreover, HEN-based crosslinkers are designed to enhance the resulting thermomechanical properties at high temperatures (>200 °C). The versatility of such materials is demonstrated through direct ink writing (DIW) to rapidly produce 3D structures without the need for printed supports. This research significantly extends the range of monomers suitable for FROMP, furthering efficient production of high-performance polymeric materials.

Synergistic Dual-Cure Reactions for the Fabrication of Thermosets by Chemical Heating

Large composite structures, such as those used in wind energy applications, rely on the bulk polymerization of thermosets on an impressively large scale. To accomplish this, traditional thermoset polymerizations require both elevated temperatures (>100 °C) and extended cure durations (>5 h) for complete conversion, necessitating the use of oversize ovens or heated molds. In turn, these requirements lead to energy-intensive polymerizations, incurring high manufacturing costs and process emissions. In this study, we develop thermoset polymerizations that can be initiated at room temperature through a transformative "chemical heating" concept, in which the exothermic energy of a secondary reaction is used to facilitate the heating of a primary thermoset polymerization. By leveraging a redox-initiated methacrylate free radical polymerization as a source of exothermic chemical energy, we can achieve peak reaction temperatures >140 °C to initiate the polymerization of epoxy-anhydride thermosets without external heating. Furthermore, by employing Trojan horse methacrylate monomers to induce mixing between methacrylate and epoxy-anhydride domains, we achieve the synthesis of homogeneous hybrid polymeric materials with competitive thermomechanical properties and tunability. Herein, we establish a proof-of-concept for our innovative chemical heating method and advocate for its industrial integration for more energy-efficient and streamlined manufacturing of wind blades and large composite parts more broadly.

A Mechanism-Based Reaction-Diffusion Model for Accelerated Discovery of Thermoset Resins Frontally Polymerized by Olefin Metathesis

Frontal ring-opening metathesis polymerization (FROMP) involves a self-perpetuating exothermic reaction, which enables the rapid and energy-efficient manufacturing of thermoset polymers and composites. Current state-of-the-art reaction-diffusion FROMP models rely on a phenomenological description of the olefin metathesis kinetics, limiting their ability to model the governing thermo-chemical FROMP processes. Furthermore, the existing models are unable to predict the variations in FROMP kinetics with changes in the resin composition and as a result are of limited utility toward accelerated discovery of new resin formulations. In this work, we formulate a chemically meaningful model grounded in the established mechanism of ring-opening metathesis polymerization (ROMP). Our study aims to validate the hypothesis that the ROMP mechanism, applicable to monomer-initiator solutions below 100 °C, remains valid under the nonideal conditions encountered in FROMP, including ambient to >200 °C temperatures, sharp temperature gradients, and neat monomer environments. Through extensive simulations, we demonstrate that our mechanism-based model accurately predicts the FROMP behavior across various resin compositions, including polymerization front velocities and thermal characteristics (e.g., Tmax). Additionally, we introduce a semi-inverse workflow that predicts FROMP behavior from a single experimental data point. Notably, the physiochemical parameters utilized in our model can be obtained through DFT calculations and minimal experiments, highlighting the model's potential for rapid screening of new FROMP chemistries in pursuit of thermoset polymers with superior thermo-chemo-mechanical properties.

Porous Polypyrrolidines for Highly Efficient Recovery of Precious Metals through Reductive Adsorption Mechanism

The recycling and utilization of precious metals have emerged as a critical research focus in advancing the development of the circular economy. Among numerous methods for recovering precious metals such as gold, adsorbents with both high adsorption selectivity and capacity have become key technologies. This article incorporated the N-phenylpyrrolidine into a flexible porous polynorbornene backbone to create a class of distinctive porous organic polymers, named BIT-POP-14-BIT-POP-17. Through a reductive capture mechanism, the reductive adsorption sites of N-phenylpyrrolidine coordinate selectively with precious metals, the reduced metal is captured by the hierarchically porous polymers with flexible backbone. This approach leads to remarkable gold recovery efficiency, achieving a record of 2321 mg g-1 at ambient conditions, and 3020 mg g-1 under UV light, surpassing the theoretical limit. The porous polymers are filled in a column for a continuous uptake of gold from waste printed circuit boards (PCBs), showing recovery efficiency toward gold as high as 95% after 84 h. Overall, this work offers a new perspective on designing novel adsorbents for precious metal recovery, providing inspiration for researchers to explore novel adsorption modes and contribute to the advancement of the circular economy.

Reprocessability in Engineering Thermosets Achieved Through Frontal Ring-Opening Metathesis Polymerization

While valued for their durability and exceptional performance, crosslinked thermosets are challenging to recycle and reuse. Here, inherent reprocessability in industrially relevant polyolefin thermosets is unveiled. Unlike prior methods, this approach eliminates the need to introduce exchangeable functionality to regenerate the material, relying instead on preserving the activity of the metathesis catalyst employed in the curing reaction. Frontal ring-opening metathesis polymerization (FROMP) proves critical to preserving this activity. Conditions controlling catalytic viability are explored to successfully reclaim performance across multiple generations of material, thus demonstrating long-term reprocessability. This straightforward and scalable remolding strategy is poised for widespread adoption. Given the anticipated growth in polyolefin thermosets, these findings represent an important conceptual advance in the pursuit of a fully circular lifecycle for thermoset polymers.

Noncontact Microfluidics of Highly Viscous Liquids for Accurate Self-Splitting and Pipetting

Accurate dosing for various liquids, especially for highly viscous liquids, is fundamental in wide-ranging from molecular crosslinking to material processing. Despite droppers or pipettes being widely used as pipetting devices, they are powerless for quantificationally splitting and dosing highly viscous liquids (>100 mPa s) like polymer liquids due to the intertwined macromolecular chains and strong cohesion energy. Here, a highly transparent photopyroelectric slippery (PS) platform is provided to achieve noncontact self-splitting for liquids with viscosity as high as 15 000 mPa s, just with the assistance of sunlight and a cooling source to provide a local temperature difference (ΔT). Moreover, to guarantee the accuracy for pipetting liquids (>80%), the ultrathin MXene film (within a thickness of 20 nm) is self-assembled as the photo-thermal layers, overcoming the trade-off between transparency and photothermal property. Compared with traditional pipetting strategies (≈1.3% accuracy for pipetting polymer liquids), this accurate microfluidic chip shows great potential in adhesive systems (bonding strength, twice than using the droppers or pipettes).

Frontal Polymerization for the Rapid Obtainment of Polymer Composites

Among the different polymerization techniques, frontal polymerization (FP) has gained high interest from the scientific community because of its peculiar characteristics: in particular, compared to classic polymerization reactions, FP allows for a better exploitation of the heat of polymerization involved, without requiring any external energy input apart from an initial photo or thermal ignition that triggers the reaction. The latter usually propagates in a few tenths of seconds or (at most) minutes through a hot self-sustaining polymerization front, giving rise to the formation of fully cured thermosetting networks or thermoplastic polymers. Furthermore, different polymerization mechanisms can be involved in FP reactions, comprising cationic or anionic, ring-opening metathesis, and free-radical polymerization, among others. Further, it is possible to run FP reactions in bulk, in solution, or even using solid monomers if they are melted at the temperature of the front, notwithstanding the possibility of using reactive systems containing fillers or fiber/fabric reinforcements. In this context, the use of FP is becoming very important also for the design and production of advanced (nano)composite materials, saving processing time and achieving the completeness of the curing reaction, even in the presence of high filler/reinforcement loadings. Therefore, this mini-review aims to provide the reader with the basics of FP and its main peculiarities, even in the context of preparing high-performing composites. In this respect, some recent case studies witnessing the potentialities of frontal polymerization for the design of advanced (nano)composite systems will be elucidated. Finally, some perspectives about possible future developments will be proposed.

Effects of the Biomimetic Microstructure in Electrospun Fiber Sutures and Mechanical Tension on Tissue Repair

Electrospun microfibers, designed to emulate the extracellular matrix (ECM), play a crucial role in regulating the cellular microenvironment for tissue repair. Understanding their mechanical influence and inherent biological interactions at the ECM interface, however, remains a complex challenge. This study delves into the role of mechanical cues in tissue repair by fabricating Col/PLCL microfibers with varying chemical compositions and alignments that mimic the structure of the ECM. Furthermore, we optimized these microfibers to create the Col/PLCL@PDO aligned suture, with a specific emphasis on mechanical tension in tissue repair. The result reveals that within fibers of identical chemical composition, fibroblast proliferation is more pronounced in aligned fibers than in unaligned ones. Moreover, cells on aligned fibers exhibit an increased aspect ratio. In vivo experiments demonstrated that as the tension increased to a certain level, cell proliferation augmented, cells assumed more elongated morphologies with distinct protrusions, and there was an elevated secretion of collagen III and tension suture, facilitating soft tissue repair. This research illuminates the structural and mechanical dynamics of electrospun fiber scaffolds; it will provide crucial insights for the advancement of precise and controllable tissue engineering materials.

Using Data Science Tools to Reveal and Understand Subtle Relationships of Inhibitor Structure in Frontal Ring-Opening Metathesis Polymerization

The rate of frontal ring-opening metathesis polymerization (FROMP) using the Grubbs generation II catalyst is impacted by both the concentration and choice of monomers and inhibitors, usually organophosphorus derivatives. Herein we report a data-science-driven workflow to evaluate how these factors impact both the rate of FROMP and how long the formulation of the mixture is stable (pot life). Using this workflow, we built a classification model using a single-node decision tree to determine how a simple phosphine structural descriptor (Vbur-near) can bin long versus short pot life. Additionally, we applied a nonlinear kernel ridge regression model to predict how the inhibitor and selection/concentration of comonomers impact the FROMP rate. The analysis provides selection criteria for material network structures that span from highly cross-linked thermosets to non-cross-linked thermoplastics as well as degradable and nondegradable materials.

Degree of Cure, Microstructures, and Properties of Carbon/Epoxy Composites Processed via Frontal Polymerization

The frontal polymerization (FP) of carbon/epoxy (C/Ep) composites is investigated, considering FP as a viable route for the additive manufacturing (AM) of thermoset composites. Neat epoxy (Ep) resin-, short carbon fiber (SCF)-, and continuous carbon fiber (CCF)-reinforced composites are considered in this study. The evolution of the exothermic reaction temperature, polymerization frontal velocity, degree of cure, microstructures, effects of fiber concentration, fracture surface, and thermal and mechanical properties are investigated. The results show that exothermic reaction temperatures range between 110 °C and 153 °C, while the initial excitation temperatures range from 150 °C to 270 °C. It is observed that a higher fiber content increases cure time and decreases average frontal velocity, particularly in low SCF concentrations. This occurs because resin content, which predominantly drives the exothermic reaction, decreases with increased fiber content. The FP velocities of neat Ep resin- and SCF-reinforced composites are seen to be 0.58 and 0.50 mm/s, respectively. The maximum FP velocity (0.64 mm/s) is observed in CCF/Ep composites. The degree of cure (αc) is observed to be in the range of 70% to 85% in FP-processed composites. Such a range of αc is significantly low in comparison to traditional composites processed through a long cure cycle. The glass transition temperature (Tg) of neat epoxy resin is seen to be approximately 154 °C, and it reduces slightly to a lower value (149 °C) for SCF-reinforced composites. The microstructures show significantly high void contents (12%) and large internal cracks. These internal cracks are initiated due to high thermal residual stress developed during curing for non-uniform temperature distribution. The tensile properties of FP-cured samples are seen to be inferior in comparison to autoclave-processed neat epoxy. This occurs mostly due to the presence of large void contents, internal cracks, and a poor degree of cure. Finally, a highly efficient and controlled FP method is desirable to achieve a defect-free microstructure with improved mechanical and thermal properties.

Exploring the Synthesis of Self-Organization and Active Motion

Proteins, genetic material, and membranes are fundamental to all known organisms, yet these components alone do not constitute life. Life emerges from the dynamic processes of self-organization, assembly, and active motion, suggesting the existence of similar artificial systems. Against this backdrop, our Perspective explores a variety of chemical phenomena illustrating how nonequilibrium self-organization and micromotors contribute to life-like behavior and functionalities. After explaining key terms, we discuss specific examples including enzymatic motion, diffusiophoretic and bubble-driven self-propulsion, pattern-forming reaction-diffusion systems, self-assembling inorganic aggregates, and hierarchically emergent phenomena. We also provide a roadmap for combining self-organization and active motion and discuss possible outcomes through biological analogs. We suggest that this research direction, deeply rooted in physical chemistry, offers opportunities for further development with broad impacts on related sciences and technologies.

Polymer Patterning by Laser-Induced Multipoint Initiation of Frontal Polymerization

Frontal polymerization (FP) is an approach for thermosetting plastics at a lower energy cost than an autoclave. The potential to generate simultaneous propagation of multiple polymerization fronts has been discussed as an exciting possibility. However, FP initiated at more than two points simultaneously has not been demonstrated. Multipoint initiation could enable both large-scale material fabrication and unique pattern generation. Here, the authors present laser-patterned photothermal heating as a method for simultaneous initiation of FP at multiple locations in a 2-D sample. Carbon black particles are mixed into liquid resin (dicyclopentadiene) to enhance absorption of light from a Ti:sapphire laser (800 nm) focused on a sample. The laser is time-shared by rapid steering among initiation points, generating polymerization using up to seven simultaneous points of initiation. This process results in the formation of both symmetric and asymmetric seam patterns resulting from the collision of fronts. The authors also present and validate a theoretical framework for predicting the seam patterns formed by front collisions. This framework allows the design of novel patterns via an inverse solution for determining the initiation points required to form a desired pattern. Future applications of this approach could enable rapid, energy-efficient manufacturing of novel composite-like patterned materials.

Unraveling Reactivity Differences: Room-Temperature Ring-Opening Metathesis Polymerization (ROMP) versus Frontal ROMP

In this study, we explore the distinct reactivity patterns between frontal ring-opening metathesis polymerization (FROMP) and room-temperature solventless ring-opening metathesis polymerization (ROMP). Despite their shared mechanism, we find that FROMP is less sensitive to inhibitor concentration than room-temperature ROMP. By increasing the initiator-to-monomer ratio for a fixed inhibitor/initiator quantity, we find reduction in the ROMP background reactivity at room temperature (i.e., increased resin pot life). At elevated temperatures where inhibitor dissociation prevails, accelerated frontal polymerization rates are observed because of the concentrated presence of the initiator. Surprisingly, the strategy of employing higher initiator loading enhances both pot life and front speeds, which leads to FROMP rates exceeding prior reported values by over 5 times. This counterintuitive behavior is attributed to an increase in the proximity of the inhibitor to the initiator within the bulk resin and to whether the temperature favors coordination or dissociation of the inhibitor. A rapid method was developed for assessing resin pot life, and a straightforward model for active initiator behavior was established. Modified resin systems enabled direct ink writing of robust thermoset structures at rates much faster than previously possible.

Free-Standing 3D Printing of Epoxy-Vinyl Ether Structures Using Radical-Induced Cationic Frontal Polymerization

The application of frontal polymerization to additive manufacturing has advantages in energy consumption and speed of printing. Additionally, with frontal polymerization, it is possible to print free-standing structures that require no supports. A resin was developed using a mixture of epoxies and vinyl ether with an iodonium salt and peroxide initiating system that frontally polymerizes through radical-induced cationic frontal polymerization. The formulation, which was optimized for reactivity, physical properties, and rheology, allowed the printing of free-standing structures. Increasing ratios of vinyl ether and reactive cycloaliphatic epoxide were found to increase the front velocity. Addition of carbon nanofibers increased the front velocity more than the addition of milled carbon fibers. The resin filled with carbon nanofibers and fumed silica exhibited shear-thinning behavior and was suitable for extrusion-based printing at a weight fraction of 4 wt %. A desktop 3D printer was modified to control resin extrusion and deposition with a digital syringe dispenser. Flexural properties of molded and 3D-printed specimens showed that specimens printed in the transverse direction exhibited the lowest strength, likely due to the presence of voids, adhesion issues between filaments, and preferential carbon nanofiber alignment along the filaments. Finally, free-standing printing of single, angled filaments and helical geometries was successfully demonstrated by coordinating ultraviolet-based reaction initiation, low air pressure for resin extrusion, and printing speed to match front velocity.

A Self-Healing System for Polydicyclopentadiene Thermosets

Self-healing offers promise for addressing structural failures, increasing lifespan, and improving durability in polymeric materials. Implementing self-healing in thermoset polymers faces significant manufacturing challenges, especially due to the elevated temperature requirements of thermoset processing. To introduce self-healing into structural thermosets, the self-healing system must be thermally stable and compatible with the thermoset chemistry. This article demonstrates a self-healing microcapsule-based system stable to frontal polymerization (FP), a rapid and energy-efficient manufacturing process with a self-propagating exothermic reaction (≈200 °C). A thermally latent Grubbs-type complex bearing two N-heterocyclic carbene ligands addresses limitations in conventional G2-based self-healing approaches. Under FP's elevated temperatures, the catalyst remains dormant until activated by a Cu(I) co-reagent, ensuring efficient polymerization of the dicyclopentadiene (DCPD) upon damage to the polyDCPD matrix. The two-part microcapsule system consists of one capsule containing the thermally latent Grubbs-type catalyst dissolved in the solvent, and another capsule containing a Cu(I) coagent blended with liquid DCPD monomer. Using the same chemistry for both matrix fabrication and healing results in strong interfaces as demonstrated by lap-shear tests. In an optimized system, the self-healing system restores the mechanical properties of the tough polyDCPD thermoset. Self-healing efficiencies greater than 90% via tapered double cantilever beam tests are observed.

Rapid Synthesis of Robust Antibacterial and Biodegradable Hydrogels via Frontal Polymerization

Chitosan (CS) is widely used in biomedical hydrogels due to their similarity to extracellular matrix. However, the preparation method of CS-based hydrogel suffers the drawbacks of tedious operation, time-consuming and energy consumption. Thus, there is an urgent need to develop a rapid synthesis pathway towards hydrogels. In this work, we used a modified CS as a cross-linking agent and acrylic acid (AA) as monomer to prepare a hydrogel through frontal polymerization (FP), which facilitates a facile and rapid method achieved in several minutes. The occurrence of pure FP was confirmed via the frontal velocity and temperature profile measurement. In addition, the as-prepared hydrogel shows excellent mechanical strength up to 1.76 MPa, and the Young's modulus (ranging from 0.16 to 0.56 MPa) is comparable to human skin. The degradation mechanism is revealed by the micro-IR images through the distribution of the functional groups, which is attributed to the breakage of the ether bond. Moreover, the hydrogel exhibits excellent degradability, biocompatibility and antibacterial properties, offering great potentials in tissue engineering. We believe this work not only offers a facile and rapid FP method to fabricate a robust degradable hydrogel, but also provides an effective pathway for the investigation of the degradation mechanism at the chemical bond analysis level.

Polymer Hydrogels and Frontal Polymerization: A Winning Coupling

Polymer hydrogels are 3D networks consisting of hydrophilic crosslinked macromolecular chains, allowing them to swell and retain water. Since their invention in the 1960s, they have become an outstanding pillar in the design, development, and application of engineered polymer systems suitable for biomedical and pharmaceutical applications (such as drug or cell delivery, the regeneration of hard and soft tissues, wound healing, and bleeding prevention, among others). Despite several well-established synthetic routes for developing polymer hydrogels based on batch polymerization techniques, about fifteen years ago, researchers started to look for alternative methods involving simpler reaction paths, shorter reaction times, and lower energy consumption. In this context, frontal polymerization (FP) has undoubtedly become an alternative and efficient reaction model that allows for the conversion of monomers into polymers via a localized and propagating reaction-by means of exploiting the formation and propagation of a "hot" polymerization front-able to self-sustain and propagate throughout the monomeric mixture. Therefore, the present work aims to summarize the main research outcomes achieved during the last few years concerning the design, preparation, and application of FP-derived polymeric hydrogels, demonstrating the feasibility of this technique for the obtainment of functional 3D networks and providing the reader with some perspectives for the forthcoming years.

Redox cationic frontal polymerization: a new strategy towards fast and efficient curing of defect-free fiber reinforced polymer composites

Frontal polymerization of epoxy-based thermosets is a promising curing technique for the production of carbon fiber reinforced composites (CFRCs). It exploits the exothermicity of polymerization reactions to convert liquid monomers to a solid 3D network. A self-sustaining curing reaction is triggered by heat or UV-radiation, resulting in a localized thermal reaction zone that propagates through the resin formulation. To date, frontal polymerization is limited to CFRCs with a low fiber volume percent as heat losses compromise on the propagation of the heat front, which is crucial for this autocatalytic curing mechanism. In addition, the choice of suitable epoxy monomers and thermal radical initiators is limited, as highly reactive cycloaliphatic epoxies as well as peroxides decarboxylate during radical induced cationic frontal polymerization. The resulting networks suffer from high defect rates and inferior mechanical properties. Herein, we overcome these shortcomings by introducing redox cationic frontal polymerization (RCFP) as a new frontal curing concept. In the first part of this study, the influence of stannous octoate (reducing agent) was studied on a frontally cured bisphenol A diglycidyl ether resin and mechanical and thermal properties were compared to a conventional anhydride cured counterpart. In a subsequent step, a quasi-isotropic CFRC with a fiber volume of >50 vol%, was successfully cured via RCFP. The composite exhibited a glass transition temperature > 100 °C and a low number of defects. Finally, it was demonstrated that the redox agent effectively prevents decarboxylation during frontal polymerization of a cycloaliphatic epoxy, demonstrating the versatility of RCFP in future applications.

Influence of Catalyst Content and Epoxy/Carboxylate Ratio on Isothermal Creep of Epoxy Vitrimers

In the present work, a commercial epoxy based on epoxy anhydride and tertiary amine was modified by a metallic catalyst (Zn2+) to induce vitrimeric behavior by promoting the transesterification reaction. The effect of two different epoxy/acid ratios (1 and 0.6) at two different zinc acetate amounts (Zn(Ac)2) on the thermomechanical and viscoelastic performances of the epoxy vitrimers were investigated. Creep experiments showed an increase in molecular mobility above the critical "Vitrimeric" temperature (Tv) of 170 °C proportionally to the amount of Zn(Ac)2. A procedure based on Burger's model was set up to investigate the effect of catalyst content on the vitrimer ability to flow as the effect of the dynamic exchange reaction. The analysis showed that in the case of a balanced epoxy/acid formulation, the amount of catalyst needed for promoting molecular mobility is 5%. This system showed a value of elastic modulus and dynamic viscosity at 170 °C of 9.50 MPa and 2.23 GPas, respectively. The material was easily thermoformed in compression molding, paving the way for the recyclability and weldability of the thermoset system.

An Investigation of the Healing Efficiency of Epoxy Vitrimer Composites Based on Zn2+ Catalyst

The need to recycle carbon-fibre-reinforced composite polymers (CFRP) has grown significantly to reduce the environmental impact generated by their production. To meet this need, thermoreversible epoxy matrices have been developed in recent years. This study investigates the performance of an epoxy vitrimer made by introducing a metal catalyst (Zn2+) and its carbon fibre composites, focusing on the healing capability of the system. The dynamic crosslinking networks endow vitrimers with interesting rheological behaviour; the capability of the formulated resin (AV-5) has been assessed by creep tests. The analysis showed increased molecular mobility above a topology freezing temperature (Tv). However, the reinforcement phase inhibits the flow capability, reducing the flow. The fracture behaviour of CFRP made with the vitrimeric resin has been investigated by Mode I and Mode II tests and compared with the conventional system. The repairability of the vitrimeric CFRP has been investigated by attempting to recover the delaminated samples, which yielded unsatisfactory results. Moreover, the healing efficiency of the modified epoxy composites has been assessed using the vitrimer as an adhesive layer. The joints were able to recover about 84% of the lap shear strength of the pristine system.

Kinetic and Chemical Effects of Clays and Other Fillers in the Preparation of Epoxy-Vinyl Ether Composites Using Radical-Induced Cationic Frontal Polymerization

Addition of fillers to formulations can generate composites with improved mechanical properties and lower the overall cost through a reduction of chemicals needed. In this study, fillers were added to resin systems consisting of epoxies and vinyl ethers that frontally polymerized through a radical-induced cationic frontal polymerization (RICFP) mechanism. Different clays, along with inert fumed silica, were added to increase the viscosity and reduce the convection, results of which did not follow many trends present in free-radical frontal polymerization. The clays were found to reduce the front velocity of RICFP systems overall compared to systems with only fumed silica. It is hypothesized that chemical effects and water content produce this reduction when clays are added to the cationic system. Mechanical and thermal properties of composites were studied, along with filler dispersion in the cured material. Drying the clays in an oven increased the front velocity. Comparing thermally insulating wood flour to thermally conducting carbon fibers, we observed that the carbon fibers resulted in an increase in front velocity, while the wood flour reduced the front velocity. Finally, it was shown that acid-treated montmorillonite K10 polymerizes RICFP systems containing vinyl ether even in the absence of an initiator, resulting in a short pot life.

Facile Obtainment of Fluorescent PEG Hydrogels Bearing Pyrene Groups by Frontal Polymerization

Frontal polymerization (FP) was used to prepare poly(ethylene glycol) methyl ether acrylate (PEGMA) fluorescent polymer hydrogels containing pyrenebutyl pendant groups as fluorescent probes. The polymerization procedure was carried out under solvent-free conditions, with different molar quantities of pyrenebutyl methyl ether methacrylate (PybuMA) and PEGMA, in the presence of tricaprylmethylammonium (Aliquat 336®) persulfate as a radical initiator. The obtained PEGPy hydrogels were characterized by FT-IR spectroscopy, confirming the effective incorporation of the PybuMA monomer into the polymer backbone. The thermal properties of the hydrogels were determined using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC). After immersing the hydrogels in deionized water at 25 °C and pH = 7, their swelling behavior was investigated by mass gain at different pH and temperature values. The introduction of PybuMA comonomer into the hydrogel resulted in a decreased swelling ability due to the hydrophobicity of PybuMA. The optical properties of PEGPy were determined by UV-visible absorption and fluorescence spectroscopies. Both monomer and excimer emission bands were observed at 379–397 and 486 nm, respectively, and the fluorescence spectra of the PEGPy hydrogel series were recorded in different solvents to explore the coexistence of monomer and excimer emissions.