Controlled Degradation of Cast and 3-D Printed Photocurable Thioester Networks via Thiol–Thioester Exchange

Thermally and Base-Triggered "Debond-on-Demand" Chain-Extended Polyurethane Adhesives

A series of novel chain-extended polyurethanes (CEPUs) featuring degradable sulfonyl ethyl urethane chain-extenders that permit degradation under base-triggered conditions to afford "debond-on-demand" elastomeric adhesives are reported. Exposure of the CEPUs to tetra-butylammonium fluoride (TBAF) triggered the degradation of the sulfonyl ethyl urethane chain-extenders. Lap shear adhesion tests of the CEPUs exposed to TBAF revealed reductions in shear strength of up to 65% for both aluminum and glass substrates, from 2.18 to 0.76 MPa and from 1.13 to 0.52 MPa, respectively. The selective depolymerization of these polymers makes them suitable candidates as debondable binders for inkjet inks and coatings, enabling removal of inks and adhesive residues from substrates before they enter the recycling process, to prevent surface contaminants decreasing the quality of the recycled material.

Sustainable Vat Photopolymerization-Based 3D-Printing through Dynamic Covalent Network Photopolymers

Vat photopolymerization (VPP) based three-dimensional (3D) printing, including stereolithography (SLA) and digital light projection (DLP), is known for producing intricate, high-precision prototypes with superior mechanical properties. However, the challenge lies in the non-recyclability of covalently crosslinked thermosets used in these printing processes, limiting the sustainable utilization of printed prototypes. This review paper examines the recently explored avenue of VPP 3D-printed dynamic covalent network (DCN) polymers, which enable reversible crosslinks and allow for the reprocessing of printed prototypes, promoting sustainability. These reversible crosslinks facilitate the rearrangement of crosslinked polymers, providing printed polymers with chemical/physical recyclability, self-healing capabilities, and degradability. While various mechanisms for DCN polymer systems are explored, this paper focuses solely on photocurable polymers to highlight their potential to revolutionize the sustainability of VPP 3D printing.

New Prospects Arising from Dynamically Crosslinked Polymers: Reprogramming Their Properties

Dynamically crosslinked polymers (DCPs) have gained significant attention owing to their applications in fabricating (re)processable, recyclable, and self-healable thermosets, which hold great promise in addressing ecological issues, such as plastic pollution and resource scarcity. However, the current research predominantly focuses on redefining and/or manipulating their geometries while replicating their bulk properties. Given the inherent design flexibility of dynamic covalent networks, DCPs also exhibit a remarkable potential for various novel applications through postsynthesis reprogramming their properties. In this review, the recent advancements in strategies that enable DCPs to transform their bulk properties after synthesis are presented. The underlying mechanisms and associated material properties are overviewed mainly through three distinct strategies, namely latent catalysts, material-growth, and topology isomerizable networks. Furthermore, the mutual relationship and impact of these strategies when integrated within one material system are also discussed. Finally, the application prospects and relevant issues necessitating further investigation, along with the potential solutions are analyzed.

A renewably sourced, circular photopolymer resin for additive manufacturing

The additive manufacturing of photopolymer resins by means of vat photopolymerization enables the rapid fabrication of bespoke 3D-printed parts. Advances in methodology have continually improved resolution and manufacturing speed, yet both the process design and resin technology have remained largely consistent since its inception in the 1980s1. Liquid resin formulations, which are composed of reactive monomers and/or oligomers containing (meth)acrylates and epoxides, rapidly photopolymerize to create crosslinked polymer networks on exposure to a light stimulus in the presence of a photoinitiator2. These resin components are mostly obtained from petroleum feedstocks, although recent progress has been made through the derivatization of renewable biomass3-6 and the introduction of hydrolytically degradable bonds7-9. However, the resulting materials are still akin to conventional crosslinked rubbers and thermosets, thus limiting the recyclability of printed parts. At present, no existing photopolymer resin can be depolymerized and directly re-used in a circular, closed-loop pathway. Here we describe a photopolymer resin platform derived entirely from renewable lipoates that can be 3D-printed into high-resolution parts, efficiently deconstructed and subsequently reprinted in a circular manner. Previous inefficiencies with methods using internal dynamic covalent bonds10-17 to recycle and reprint 3D-printed photopolymers are resolved by exchanging conventional (meth)acrylates for dynamic cyclic disulfide species in lipoates. The lipoate resin platform is highly modular, whereby the composition and network architecture can be tuned to access printed materials with varied thermal and mechanical properties that are comparable to several commercial acrylic resins.

Stretchable, recyclable thermosets via photopolymerization and 3D printing of hemiacetal ester-based resins

Achieving a circular plastics economy is one of our greatest environmental challenges, yet conventional mechanical recycling remains inadequate for thermoplastics and incompatible with thermosets. The next generation of plastic materials will be designed with the capacity for degradation and recycling at end-of-use. To address this opportunity in the burgeoning technologies of 3D printing and photolithography, we report a modular system for the production of degradable and recyclable thermosets via photopolymerization. The polyurethane backbone imparts robust, elastic, and tunable mechanical properties, while the use of hemiacetal ester linkages allows for facile degradation under mild acid. The synthetic design based on hemiacetal esters enables simple purification to regenerate a functional polyurethane diol.

Vat Photopolymerization Additive Manufacturing of Tough, Fully Recyclable Thermosets

To advance the capabilities of additive manufacturing, novel resin formulations are needed that produce high-fidelity parts with desired mechanical properties that are also amenable to recycling. In this work, a thiol-ene-based system incorporating semicrystallinity and dynamic thioester bonds within polymer networks is presented. It is shown that these materials have ultimate toughness values >16 MJ cm^-3, comparable to high-performance literature precedents. Significantly, the treatment of these networks with excess thiols facilitates thiol-thioester exchange that degrades polymerized networks into functional oligomers. These oligomers are shown to be amenable to repolymerization into constructs with varying thermomechanical properties, including elastomeric networks that recover their shape fully from >100% strain. Using a commercial stereolithographic printer, these resin formulations are printed into functional objects including both stiff (E ∼ 10-100 MPa) and soft (E ∼ 1-10 MPa) lattice structures. Finally, it is shown that the incorporation of both dynamic chemistry and crystallinity further enables advancement in the properties and characteristics of printed parts, including attributes such as self-healing and shape-memory.

An immunomodulatory polypeptide hydrogel for osteochondral defect repair

Osteochondral injury is a common and frequent orthopedic disease that can lead to more serious degenerative joint disease. Tissue engineering is a promising modality for osteochondral repair, but the implanted scaffolds are often immunogenic and can induce unwanted foreign body reaction (FBR). Here, we prepare a polypept(o)ide-based PAA-RGD hydrogel using a novel thiol/thioester dual-functionalized hyperbranched polypeptide P(EG₃Glu-co-Cys) and maleimide-functionalized polysarcosine under biologically benign conditions. The PAA-RGD hydrogel shows suitable biodegradability, excellent biocompatibility, and low immunogenicity, which together lead to optimal performance for osteochondral repair in New Zealand white rabbits even at the early stage of implantation. Further in vitro and in vivo mechanistic studies corroborate the immunomodulatory role of the PAA-RGD hydrogel, which induces minimum FBR responses and a high level of polarization of macrophages into the immunosuppressive M2 subtypes. These findings demonstrate the promising potential of the PAA-RGD hydrogel for osteochondral regeneration and highlight the importance of immunomodulation. The results may inspire the development of PAA-based materials for not only osteochondral defect repair but also various other tissue engineering and bio-implantation applications.

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A polypept(o)ide-based hydrogel.

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Prominent and early osteochondral repair.

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Minimized immunogenicity.

3D-Printed Microarray Patches for Transdermal Applications

The intradermal (ID) space has been actively explored as a means for drug delivery and diagnostics that is minimally invasive. Microneedles or microneedle patches or microarray patches (MAPs) are comprised of a series of micrometer-sized projections that can painlessly puncture the skin and access the epidermal/dermal layer. MAPs have failed to reach their full potential because many of these platforms rely on dated lithographic manufacturing processes or molding processes that are not easily scalable and hinder innovative designs of MAP geometries that can be achieved. The DeSimone Laboratory has recently developed a high-resolution continuous liquid interface production (CLIP) 3D printing technology. This 3D printer uses light and oxygen to enable a continuous, noncontact polymerization dead zone at the build surface, allowing for rapid production of MAPs with precise and tunable geometries. Using this tool, we are now able to produce new classes of lattice MAPs (L-MAPs) and dynamic MAPs (D-MAPs) that can deliver both solid state and liquid cargos and are also capable of sampling interstitial fluid. Herein, we will explore how additive manufacturing can revolutionize MAP development and open new doors for minimally invasive drug delivery and diagnostic platforms.

Additive manufacturing: Frameworks for chemical understanding and advancement in vat photopolymerization

Three-dimensional printing, or additive manufacturing (AM), is a broad term for a wide range of fabrication methods utilizing materials such as small-molecule, polymer, and metal feedstocks. Each method requires different chemical, physical, and engineering needs to be successful. This article will discuss some of the considerations for polymer-based AM methods. Ultimately, we focus on the chemistries of vat photopolymerization, in which light is used to cure a resin from liquid to solid, to provide an example of how chemical advancements have led to increased speed, resolution, and multimaterial printing capabilities not previously possible.