Effect of 3D-Printed Microvascular Network Design on the Self-Healing Behavior of Cross-Linked Polymers

Polymer Composites in 3D/4D Printing: Materials, Advances, and Prospects

Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionized the manufacturing landscape by enabling the intricate layer-by-layer construction of three-dimensional objects. In contrast to traditional methods relying on molds and tools, AM provides the flexibility to fabricate diverse components directly from digital models without the need for physical alterations to machinery. Four-dimensional printing is a revolutionary extension of 3D printing that introduces the dimension of time, enabling dynamic transformations in printed structures over predetermined periods. This comprehensive review focuses on polymeric materials in 3D printing, exploring their versatile processing capabilities, environmental adaptability, and applications across thermoplastics, thermosetting materials, elastomers, polymer composites, shape memory polymers (SMPs), including liquid crystal elastomer (LCE), and self-healing polymers for 4D printing. This review also examines recent advancements in microvascular and encapsulation self-healing mechanisms, explores the potential of supramolecular polymers, and highlights the latest progress in hybrid printing using polymer-metal and polymer-ceramic composites. Finally, this paper offers insights into potential challenges faced in the additive manufacturing of polymer composites and suggests avenues for future research in this dynamic and rapidly evolving field.

Self-Healing Polymeric Materials and Composites for Additive Manufacturing

Self-healing polymers have received widespread attention due to their ability to repair damage autonomously and increase material stability, reliability, and economy. However, the processability of self-healing materials has yet to be studied, limiting the application of rich self-healing mechanisms. Additive manufacturing effectively improves the shortcomings of conventional processing while increasing production speed, accuracy, and complexity, offering great promise for self-healing polymer applications. This article summarizes the current self-healing mechanisms of self-healing polymers and their corresponding additive manufacturing methods, and provides an outlook on future developments in the field.

Current Self-Healing Binders for Energetic Composite Material Applications

Energetic composite materials (ECMs) are the basic materials of polymer binder explosives and composite solid propellants, which are mainly composed of explosive crystals and binders. During the manufacturing, storage and use of ECMs, the bonding surface is prone to micro/fine cracks or defects caused by external stimuli such as temperature, humidity and impact, affecting the safety and service of ECMs. Therefore, substantial efforts have been devoted to designing suitable self-healing binders aimed at repairing cracks/defects. This review describes the research progress on self-healing binders for ECMs. The structural designs of these strategies to manipulate macro-molecular and/or supramolecular polymers are discussed in detail, and then the implementation of these strategies on ECMs is discussed. However, the reasonable configuration of robust microstructures and effective dynamic exchange are still challenges. Therefore, the prospects for the development of self-healing binders for ECMs are proposed. These critical insights are emphasized to guide the research on developing novel self-healing binders for ECMs in the future.

An Overview of Self-Healable Polymers and Recent Advances in the Field

The search for materials with better performance, longer service life, lower environmental impact, and lower overall cost is at the forefront of polymer science and material engineering. This has led to the development of self-healing polymers with a range of healing mechanisms including capsular-based, vascular, and intrinsic self-healing polymers. The development of self-healable systems has been inspired by the healing of biological systems such as skin wound healing and broken bone reconstruction. The goal of using self-healing polymers in various applications is to extend the service life of polymers without the need for replacement or human intervention especially in restricted access areas such as underwater/underground piping where inspection, intervention, and maintenance are very difficult. Through an industrial and scholarly lens, this paper provides (a) an overview of self-healing polymers, (b) classification of different self-healing polymers and polymer-based composites, (c) mechanical, thermal, and electrical analysis characterization, (d) applications in coating, composites, and electronics, (e) modeling and simulation, and (f) recent development in the past 20 years . This review highlights the importance of healable polymers for an economically and environmentally sustainable future, the most recent advances in the field, and current limitations in fabrication, manufacturing, and performance. This article is protected by copyright. All rights reserved.

Material Design for Enhancing Properties of 3D Printed Polymer Composites for Target Applications

Polymer composites are becoming an important class of materials for a diversified range of industrial applications due to their unique characteristics and natural and synthetic reinforcements. Traditional methods of polymer composite fabrication require machining, manual labor, and increased costs. Therefore, 3D printing technologies have come to the forefront of scientific, industrial, and public attention for customized manufacturing of composite parts having a high degree of control over design, processing parameters, and time. However, poor interfacial adhesion between 3D printed layers can lead to material failure, and therefore, researchers are trying to improve material functionality and extend material lifetime with the addition of reinforcements and self-healing capability. This review provides insights on different materials used for 3D printing of polymer composites to enhance mechanical properties and improve service life of polymer materials. Moreover, 3D printing of flexible energy-storage devices (FESD), including batteries, supercapacitors, and soft robotics using soft materials (polymers), is discussed as well as the application of 3D printing as a platform for bioengineering and earth science applications by using a variety of polymer materials, all of which have great potential for improving future conditions for humanity and planet Earth.

[Application and potential future directions of self-healing polymers in dentistry]

Self-healing materials have rapidly developed in recent years to overcome the micro-cracks occurring in the polymer matrix. Self-healing ability offers autonomous crack repairs to prolong the service lives of polymers or polymer composites. As a main approach, extrinsic self-healing materials based on microcapsules have been applied in dentistry recently. This paper comprehensively presented and reviewed the definition and classification of self-healing materials, the synthesis of microcapsules, the calculation of self-healing efficiency, and the application of self-healing materials in dentistry. The future directions of self-healing polymers are also discussed.

Permeability and mechanical properties of gradient porous PDMS scaffolds fabricated by 3D-printed sacrificial templates designed with minimal surfaces

In the present study, polydimethylsiloxane (PDMS) porous scaffolds are designed based on minimal surface architectures and fabricated through a low-cost and accessible sacrificial mold printing approach using a fused deposition modeling (FDM) 3D printer. The effects of pore characteristics on compressive properties and fluid permeability are studied. The results suggest that radially gradient pore distribution (as a potential way to enhance mechanically-efficient scaffolds with enhanced cell/scaffold integration) has higher elastic modulus and fluid permeability compared to their uniform porosity counterparts. Also, the scaffolds are fairly strain-reversible under repeated loading of up to 40% strain. Among different triply periodic minimal surface pore architectures, P-surface was observed to be stiffer, less permeable and have lower densification strain compared to the D-surface and G-surface-based pore shapes. The biocompatibility of the created scaffolds is assessed by filling the PDMS scaffolds using mouse embryonic fibroblasts with cell-laden gelatin methacryloyl which was cross-linked in situ by UV light. Cell viability is found to be over 90% after 4 days in 3D culture. This method allows for effectively fabricating biocompatible porous organ-shaped scaffolds with detailed pore features which can potentially tailor tissue regenerative applications. STATEMENT OF SIGNIFICANCE: Printing polymers with chemical curing mechanism required for materials such as PDMS is challenging and impossible to create high-resolution uniformly cured structures due to hard control on the base polymer and curing process. An interconnected porous mold with ordered internal architecture with complex geometries were 3D printed using low-cost and accessible FDM technology. The mold acted as a 3D sacrificial material to form internally architected flexible PDMS scaffolds for tissue engineering applications. The scaffolds are mechanically stable under high strain cyclic loads and provide enough pore and space for viably integrating cells within the gradient architecture in a controllable manner.

Generation of Cost-Effective Paper-Based Tissue Models through Matrix-Assisted Sacrificial 3D Printing

Due to the combined advantages of cellulose and nanoscale (diameter 20-60 nm), bacterial cellulose possesses a series of attractive features including its natural origin, moderate biosynthesis process, good biocompatibility, and cost-effectiveness. Moreover, bacterial cellulose nanofibers can be conveniently processed into three-dimensional (3D) intertwined structures and form stable paper devices after simple drying. These advantages make it suitable as the material for construction of organ-on-a-chip devices using matrix-assisted sacrificial 3D printing. We successfully fabricated various microchannel structures embedded in the bulk bacterial cellulose hydrogels and retained their integrity after the drying process. Interestingly, these paper-based devices containing hollow microchannels could be rehydrated and populated with relevant cells to form vascularized tissue models. As a proof-of-concept demonstration, we seeded human umbilical vein endothelial cells (HUVECs) into the microchannels to obtain the vasculature and inoculated the MCF-7 cells onto the surrounding matrix of the paper device to build a 3D paper-based vascularized breast tumor model. The results showed that the microchannels were perfusable, and both HUVECs and MCF-7 cells exhibited favorable proliferation behaviors. This study may provide a new strategy for constructing simple and low-cost in vitro tissue models, which may find potential applications in drug screening and personalized medicine.

4D Printing of Recyclable Lightweight Architectures Using High Recovery Stress Shape Memory Polymer

High-performance lightweight architectures, such as metallic microlattices with excellent mechanical properties have been 3D printed, but they do not possess shape memory effect (SME), limiting their usages for advanced engineering structures, such as serving as a core in multifunctional lightweight sandwich structures. 3D printable self-healing shape memory polymer (SMP) microlattices could be a solution. However, existing 3D printable thermoset SMPs are limited to either low strength, poor stress memory, or non-recyclability. To address this issue, a new thermoset polymer, integrated with high strength, high recovery stress, perfect shape recovery, good recyclability, and 3D printability using direct light printing, has been developed in this study. Lightweight microlattices with various unit cells and length scales were printed and tested. The results show that the cubic microlattice has mechanical strength comparable to or even greater than that of metallic microlattices, good SME, decent recovery stress, and recyclability, making it the first multifunctional lightweight architecture (MLA) for potential multifunctional lightweight load carrying structural applications.

Stereolithographic 3D printing of extrinsically self-healing composites

We demonstrate for the first time the direct stereolithographic 3D printing of an extrinsically self-healing composite, comprised of commercial photocurable resin modified with anisole and PMMA-filled microcapsules. The composites demonstrate solvent-welding based autonomous self-healing to afford 87% recovery of the initial critical toughness. This work illustrates the potential of stereolithographic printing to fabricate self-healing composites with user-defined structures, avoiding the need for extensive rheological optimization of printing inks, like in direct-write 3D printing. Importantly, this work also demonstrates the inclusion of microcapsules into 3D printing resins to incorporate additional functionality into printed composites, which could be adapted for applications beyond self-healing materials.

Self-Reporting Fiber-Reinforced Composites That Mimic the Ability of Biological Materials to Sense and Report Damage

Sensing of damage, deformation, and mechanical forces is of vital importance in many applications of fiber-reinforced polymer composites, as it allows the structural health and integrity of composite components to be monitored and microdamage to be detected before it leads to catastrophic material failure. Bioinspired and biomimetic approaches to self-sensing and self-reporting materials are reviewed. Examples include bruising coatings and bleeding composites based on dye-filled microcapsules, hollow fibers, and vascular networks. Force-induced changes in color, fluorescence, or luminescence are achieved by mechanochromic epoxy resins, or by mechanophores and force-responsive proteins located at the interface of glass/carbon fibers and polymers. Composites can also feel strain, stress, and damage through embedded optical and electrical sensors, such as fiber Bragg grating sensors, or by resistance measurements of dispersed carbon fibers and carbon nanotubes. Bioinspired composites with the ability to show autonomously if and where they have been damaged lead to a multitude of opportunities for aerospace, automotive, civil engineering, and wind-turbine applications. They range from safety features for the detection of barely visible impact damage, to the real-time monitoring of deformation of load-bearing components.