Improving the Performance of Photoactive Terpene-Based Resin Formulations for Light-Based Additive Manufacturing

Photocurable liquid formulations have been a key research focus for the preparation of mechanically robust and thermally stable networks. However, the development of renewable resins to replace petroleum-based commodities presents a great challenge in the field. From this perspective, we disclose the design of photoactive resins based on terpenes and itaconic acid, both potentially naturally sourced, to prepare photosets with adjustable thermomechanical properties. Biobased perillyl itaconate (PerIt) was synthesized from renewable perillyl alcohol and itaconic anhydride via a scalable solvent-free method. Photoirradiation of PerIt in the presence of a multiarm thiol and photoinitiator led to the formation of networks over a range of compositions. Addition of nonmodified terpenes (perillyl alcohol, linalool, or limonene) as reactive diluents allowed for more facile preparation of photocured networks. Photosets within a wide range of properties were accessed, and these could be adjusted by varying diluent type and thiol stoichiometry. The resins showed rapid photocuring kinetics and the ability to form either brittle or elastic materials, with Young's modulus and strain at break ranging from 3.6 to 358 MPa and 15 to 367%, respectively, depending on the chemical composition of the resin. Glass transition temperatures (Tg) were influenced by thioether content, with temperatures ranging from 5 to 43 °C, and all photosets displayed good thermal resistance with Td,5% > 190 °C. Selected formulations containing PerIt and limonene demonstrated suitability for additive manufacturing technologies and high-resolution objects were printed via digital light processing (DLP). Overall, this work presents a simple and straightforward route to prepare renewable resins for rapid prototyping applications.

Lignin: A multi-faceted role/function in 3D printing inks

3D printing technology demonstrates significant potential for the rapid fabrication of tailored geometric structures. Nevertheless, the prevalent use of fossil-derived compositions in printable inks within the realm of 3D printing results in considerable environmental pollution and ecological consequences. Lignin, the second most abundant biomass source on earth, possesses attributes such as cost-effectiveness, renewability, biodegradability, and non-toxicity. Enriched with active functional groups including hydroxyl, carbonyl, carboxyl, and methyl, coupled with its rigid aromatic ring structure and inherent anti-oxidative and thermoplastic properties, lignin emerges as a promising candidate for formulating printable inks. This comprehensive review presents the utilization of lignin, either in conjunction with functional materials or through the modification of lignin derivatives, as the primary constituent (≥50 wt%) for formulating printable inks across photo-curing-based (SLA/DLP) and extrusion-based (DIW/FDM) printing technologies. Furthermore, lignin as an additive with multi-faceted roles/functions in 3D printing inks is explored. The effects of lignin on the properties of printing inks and printed objects are evaluated. Finally, this review outlines future perspectives, emphasizing key obstacles and potential opportunities for facilitating the high-value utilization of lignin in the realm of 3D printing.

Recent advances in lignin-based 3D printing materials: A mini-review

With the growing global population and rapid economic development, the demand for energy and raw materials is increasing, and the supply of fossil resources as the main source of energy and raw materials has reached a critical juncture. However, our overexploitation and overconsumption of fossil resources have led to serious problems, including environmental pollution, climate change, and ecosystem destruction. In the face of these challenges, we must recognize the negative impacts of the shortage of fossil resources and actively seek sustainable alternative sources of energy and resources to protect our environment and sustainable development in the future. Three-dimensional (3D) printing, an additive manufacturing technology, has been used in many fields to manufacture complex and high-precision products. While traditional manufacturing processes typically produce large amounts of waste and emissions that are harmful to the environment, 3D printing is much more energy efficient compared to traditional manufacturing methods, which helps to lower energy costs and reduce reliance on non-renewable energy sources. The development of low-carbon and environmentally friendly 3D printing materials can help to reduce carbon emissions and environmental pollution and realize the goal of sustainable development. Lignin, as the second largest renewable green biomass resource after cellulose, has great potential for manufacturing low-carbon and environmentally friendly 3D printing materials. This review presents some recent studies on the applications of lignin and its derivatives in photo-curing 3D printing, including the preparation and performance of lignin-based photosensitive prepolymers, lignin-based reactive diluents, lignin-based photo-initiators, and lignin-based additive. This review also provides recent studies on the preparation and performance of lignin-based thermoplastic polymer for Fused Deposition Modeling (FDM) 3D printing. Finally, the future challenges and industrialization prospects of lignin-based 3D printing materials are discussed.

Straightforward Enzymatic Methacrylation of Poly(Glycerol Adipate) for Potential Applications as UV Curing Systems

Enzymatic one-pot synthesis procedures in a one-step and two-step monomers addition were developed to obtain poly(glycerol adipate) macromers with methacrylate end-functional groups under the presence of 1 and 3 wt% of Candida antarctica lipase B (CALB). Glycerol, divinyl adipate, and vinyl methacrylate were enzymatically reacted (vinyl methacrylate was either present from the beginning in the monomers solution or slowly dropped after 6 h of reaction) in tetrahydrofuran (THF) at 40 °C over 48 h. Macromers with a methacrylate end groups fraction of ≈52% in a simple one-pot one-step procedure were obtained with molecular weights (M_n) of ≈7500-7900 g/mol. The obtained products under the one-pot one-step and two steps synthesis procedures carried out using 1 and 3 wt% of a CALB enzymatic catalyst were profusely characterized by NMR (¹H and ¹³C), MALDI-TOF MS, and SEC. The methacrylate functional macromers obtained with the different procedures and 1 wt% of CALB were combined with an Irgacure^® 369 initiator to undergo homopolymerization under UV irradiation for 10 and 30 min, in order to test their potential to obtain amorphous networks within minutes with similar properties to those typically obtained by complex acrylation/methacrylation procedures, which need multiple purification steps and harsh reagents such as acyl chlorides. To the best of our knowledge, this is the first time that it has been demonstrated that the obtention of methacrylate-functional predominantly linear macromers based on poly(glycerol adipate) is able to be UV crosslinked in a simple one-step procedure.

Engineering Innovations, Challenges, and Opportunities for Lignocellulosic Biorefineries: Leveraging Biobased Polymer Production

Alternative polymer feedstocks are highly desirable to address environmental, social, and security concerns associated with petrochemical-based materials. Lignocellulosic biomass (LCB) has emerged as one critical feedstock in this regard because it is an abundant and ubiquitous renewable resource. LCB can be deconstructed to generate valuable fuels, chemicals, and small molecules/oligomers that are amenable to modification and polymerization. However, the diversity of LCB complicates the evaluation of biorefinery concepts in areas including process scale-up, production outputs, plant economics, and life-cycle management. We discuss aspects of current LCB biorefinery research with a focus on the major process stages, including feedstock selection, fractionation/deconstruction, and characterization, along with product purification, functionalization, and polymerization to manufacture valuable macromolecular materials. We highlight opportunities to valorize underutilized and complex feedstocks, leverage advanced characterization techniques to predict and manage biorefinery outputs, and increase the fraction of biomass converted into valuable products.

Biobased Photopolymer Resin for 3D Printing Containing Dynamic Imine Bonds for Fast Reprocessability

Acrylic photopolymer resins are widely used in stereolithographic 3D printing. However, the growing demand for such thermosetting resins is weighing on global issues such as waste management and fossil fuel consumption. Therefore, there is an increasing demand for reactive components that are biobased and enable recyclability of the resulting thermoset products. In this work, the synthesis of a photo-cross-linkable molecule containing dynamic imine bonds based on biobased vanillin and dimer fatty diamine is described. Using the biobased building blocks, formulations containing reactive diluent and a photoinitiator were prepared. The mixtures could be rapidly cross-linked under UV light, yielding vitrimers. Using digital light processing, 3D-printed parts were prepared, which were rigid, thermally stable, and reprocessed within 5 min at elevated temperature and pressure. The addition of a building block containing a higher concentration of imine bonds accelerated the stress relaxation and improved the mechanical rigidity of the vitrimers. This work will contribute to the development of biobased and recyclable 3D-printed resins to facilitate the transition to a circular economy.

Photocured Poly(Mannitol Sebacate) with Functional Methacrylic Monomer: Analysis of Physical, Chemical, and Biological Properties

In this work, we described the formation of polymeric networks with potential antimicrobial character based on an acrylate oligomer, poly(mannitol sebacate) (PMS), and an enzymatically synthesized methacrylic monomer with thiazole groups (MTA). Networks with different content of MTA were prepared, and further physico-chemically characterized by microhardness, water contact angle measurements, and differential scanning calorimetry. Monomer incorporation into the networks and subsequent quaternization to provide thiazolium moieties affected the mechanical behavior and the surface wettability of the networks. Moreover, the introduction of permanent cationic charges in the network surface could give antimicrobial activity to them. Therefore, the antibacterial behavior and the hemotoxicity were analyzed against Gram-positive and Gram-negative bacteria and red blood cells, respectively.

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.

Latest Trends in Sustainable Polymeric Food Packaging Films

Food packaging is the best way to protect food while it moves along the entire supply chain to the consumer. However, conventional food packaging poses some problems related to food wastage and excessive plastic production. Considering this, the aim of this work was to examine recent findings related to bio-based alternative food packaging films by means of conventional methodologies and additive manufacturing technologies, such as 3D printing (3D-P), with potential to replace conventional petroleum-based food packaging. Based on the findings, progress in the development of bio-based packaging films, biopolymer-based feedstocks for 3D-P, and innovative food packaging materials produced by this technology was identified. However, the lack of studies suggests that 3D-P has not been well-explored in this field. Nonetheless, it is probable that in the future this technology will be more widely employed in the food packaging field, which could lead to a reduction in plastic production as well as safer food consumption.

Methacrylated Bovine Serum Albumin and Tannic Acid Composite Materials for Three-Dimensional Printing Tough and Mechanically Functional Parts

Nature uses proteins as building blocks to create three-dimensional (3D) structural components (like spiderwebs and tissue) that are recycled within a closed loop. Furthermore, it is difficult to replicate the mechanical properties of these 3D architectures within synthetic systems. In the absence of biological machinery, protein-based materials can be difficult to process and can have a limited range of mechanical properties. Herein, we present an additive manufacturing workflow to fabricate tough, protein-based composite hydrogels and bioplastics with a range of mechanical properties. Briefly, methacrylated bovine-serum-albumin-based aqueous resins were 3D-printed using a commercial vat photopolymerization system. The printed structures were then treated with tannic acid to introduce additional non-covalent interactions and form tough hydrogels. The hydrogel material could be sutured and withstand mechanical load, even after immersion in water for 24 h. Additionally, a denaturing thermal cure could be used to virtually eliminate rehydration of the material and form a bioplastic. To highlight the functionality of this material, a bioplastic screw was 3D-printed and driven into wood without damage to the screw. Moreover, the 3D-printed constructs enzymatically degraded up to 85% after 30 days in pepsin solution. Thus, these protein-based 3D-printed constructs show great potential for biomedical devices that degrade in situ.

Defining the Macromolecules of Tomorrow through Synergistic Sustainable Polymer Research

Transforming how plastics are made, unmade, and remade through innovative research and diverse partnerships that together foster environmental stewardship is critically important to a sustainable future. Designing, preparing, and implementing polymers derived from renewable resources for a wide range of advanced applications that promote future economic development, energy efficiency, and environmental sustainability are all central to these efforts. In this Chemical Reviews contribution, we take a comprehensive, integrated approach to summarize important and impactful contributions to this broad research arena. The Review highlights signature accomplishments across a broad research portfolio and is organized into four wide-ranging research themes that address the topic in a comprehensive manner: Feedstocks, Polymerization Processes and Techniques, Intended Use, and End of Use. We emphasize those successes that benefitted from collaborative engagements across disciplinary lines.

Ambient-pressure lignin valorization to high-performance polymers by intensified reductive catalytic deconstruction

Chemocatalytic lignin valorization strategies are critical for a sustainable bioeconomy, as lignin, especially technical lignin, is one of the most available and underutilized aromatic feedstocks. Here, we provide the first report of an intensified reactive distillation–reductive catalytic deconstruction (RD-RCD) process to concurrently deconstruct technical lignins from diverse sources and purify the aromatic products at ambient pressure. We demonstrate the utility of RD-RCD bio-oils in high-performance additive manufacturing via stereolithography 3D printing and highlight its economic advantages over a conventional reductive catalytic fractionation/RCD process. As an example, our RD-RCD reduces the cost of producing a biobased pressure-sensitive adhesive from softwood Kraft lignin by up to 60% in comparison to the high-pressure RCD approach. Last, a facile screening method was developed to predict deconstruction yields using easy-to-obtain thermal decomposition data. This work presents an integrated lignin valorization approach for upgrading existing lignin streams toward the realization of economically viable biorefineries.

Eugenol, a Promising Building Block for Biobased Polymers with Cutting-Edge Properties

Biobased materials, derived from biomass building blocks, are essential in the pursuit of sustainable materials. Eugenol, a natural phenol obtained from clove oil, but also from lignin depolymerization, possesses a chemical structure that allows its easy modification to obtain a broad and versatile platform of biobased monomers. In this Perspective, an overview of the variety of reactions that have been executed on the allylic double bond, phenol hydroxyl group, aromatic ring, and methoxy group is given, focusing our attention on those to obtain monomers suitable for different polymerization reactions. Furthermore, possible applications and perspectives on the eugenol-derived materials are provided.

Superior Properties through Feedstock Development for Vat Photopolymerization Additive Manufacturing of High-Performance Biobased Feedstocks

Vat photopolymerization additive manufacturing (Vat AM) technologies have found niche industrial use being able to produce personalized parts in moderate quantity. However, Vat AM lacks in its ability to produce parts of satisfactory thermal and mechanical properties for structural applications. The purpose of this investigation was to develop high-performance resins with glass transition temperatures (Tg) above 200 °C for Vat AM, evaluate the properties of the produced thermosets and establish a structure–property relationship of the thermosets produced. Herein, we have developed SLA-type resins that feature bio-derived monomer hesperetin trimethacrylate (HTM) synthesized from the flavonone hesperetin. Diluents 4-acryloyl morpholine, styrene, 4-methyl styrene and 4-tert butylstyrene (tbutylsty) were photocured with HTM as the monomer and all produced thermosets with Tg values above 200 °C. Investigations of suitable crosslinkers urethane dimethacrylate, the vinyl ester CN 151 and Ebecryl 4859 (Eb4859) showed that each crosslinker displayed different benefits when formulated with HTM as the monomer and tbutylSty as the diluent (HTM:crosslinker:tbutylSty with mass ratio 2:1:2). The crosslinker CN 151 produced the thermoset of greatest onset of thermal decomposition temperature (T₀) of 352 °C. Eb4859 produced the thermoset of highest tensile strength, 19 ± 7 MPa, amongst the set of varied crosslinkers. The formulation featuring UDM (HTM:UDM:tbutysty) offered ease of processing and was seemingly the easiest to print. Investigations of reactive diluent showed that styrene produced the thermoset of the highest extent of cure and the overall highest tensile strength, 25 ± 5 MPa, while tbutylSty produced the thermoset with the greatest Tan-δ Tg, 231 °C. HTM was synthesized, formulated with diluents, crosslinkers and initiators. The HTM resins were then 3D printed to produce thermosets of Tg values greater than 200 °C. The polymer properties were evaluated and a structure–reactivity relationship was discussed.

Dissociative Carbamate Exchange Anneals 3D Printed Acrylates

Relative to other additive manufacturing modalities, vat photopolymerization (VP) offers designers superior surface finish, feature resolution, and throughput. However, poor interlayer network formation can limit a VP-printed part's tensile strength along the build axis. We demonstrate that the incorporation of carbamate bonds capable of undergoing dissociative exchange reactions provides improved interlayer network formation in VP-printed urethane acrylate polymers. In the presence of dibutyltin dilaurate catalyst, the exchange of these carbamate bonds enables rapid stress relaxation with an activation energy of 133 kJ/mol, consistent with a dissociative bond exchange process. Annealed XY tensile samples containing a catalyst demonstrate a 25% decrease in Young's modulus, attributed to statistical changes in network topology, while samples without a catalyst show no observable effect. Annealed ZX tensile samples printed with layers perpendicular to tensile load demonstrate an increase in elongation at break, indicative of self-healing. The strain at break for samples containing a catalyst increases from 33.9 to 56.0% after annealing but decreases from 48.1 to 32.1% after annealing in samples without a catalyst. This thermally activated bond exchange process improves the performance of VP-printed materials via self-healing across layers and provides a means to change Young's modulus after printing. Thus, the incorporation of carbamate bonds and appropriate catalysts in the VP-printing process provides a robust platform for enhancing material properties and performance.

Radical Photopolymerization Using 1,4-Dihydropyrrolo[3,2-b]pyrrole Derivatives Prepared via One-Pot Synthesis

Radical photopolymerization has attracted significant attention for manufacturing products with complicated structures. Herein, the synthesized 1,4-bis(4-bromophenyl)-2,5-bis(4-nitrophenyl)-1,4-dihydropyrrole[3,2-b]pyrrole (PyBN) is found to show varying photoactivity upon irradiation at different wavelengths. PyBN affords two main absorption bands, and its maximum absorption peak is at 462 nm, attributing to its strong intramolecular charge transfer property based on the donor-acceptor structure. It efficiently photoinitiates the radical photopolymerization of different (meth)acrylate materials under 365 and 395 nm LED irradiation. The highest double bond conversion of 99.86% is achieved for these materials. Under 470 nm LED, PyBN does not show molecular structure change from photolysis results as a result of intramolecular charge transfer. Therefore, PyBN shows wavelength-selective photoactivity with potential application in dual-wavelength volumetric additive manufacturing. A unique solid product is successfully fabricated using a 365 nm LED with co-irradiation of a 470 nm LED. Additionally, PyBN incorporating camphorquinone (CQ) as a two-component visible light photoinitiator system is investigated under 470 nm LED irradiation. As PyBN has a charge transfer activity at 470 nm, the combination with CQ exhibits a good synergistic interaction. Besides nitro-based PyBN, a methyl-based PyBC was prepared as a reference compound.

Flexible Materials for High-Resolution 3D Printing of Microfluidic Devices with Integrated Droplet Size Regulation

We develop resins for high-resolution additive manufacturing of flexible micromaterials via projection microstereolithography (PμSL) screening formulations made from monomer 2-phenoxyethyl acrylate, the cross-linkers Ebecryl 8413, tri(propyleneglycol) diacrylate or 1,3,5-triallyl-1,3,5-triazine-2,4,6(1H,3H,5H)-trione, the photoabsorber Sudan 1, and the photoinitiator diphenyl(2,4,6-trimethylbenzoyl)phosphine oxide. PμSL-printed polymer micromaterials made from this resin library are characterized regarding achievable layer thickness depending on UV exposure energy, and for mechanical as well as optical properties. The best-candidate resin from this screening approach allows for 3D-printing transparent microchannels with a minimum cross section of approximately 35 × 46 μm², which exhibit proper solvent resistance against water, isopropanol, ethanol, n-hexane, and HFE-7500. The mechanical properties are predestined for 3D-printing microfluidic devices with integrated functional units that require high material flexibility. Exemplarily, we design flexible microchannels for on-demand regulation of microdroplet sizes in microemulsion formation. Our two outlines of integrated droplet regulators operate by injecting defined volumes of air, which deform the droplet-forming microchannel cross-junction, and change the droplet size therein. With this study, we expand the library of functional resins for PμSL printing toward flexible materials with micrometer resolution and provide the basis for further exploration of these materials, e.g., as microstructured cell-culturing substrates with defined mechanics.

Development of Photosensitive Natural Rubber as a Mechanical Modifier for Ultraviolet-Curable Resin Applied in Digital Light Processing-Based Three-Dimensional Printing Technology

Natural rubber (NR), a natural product from the Hevea brasiliensis tree, has been developed as a photosensitive mechanical modifier utilized in lithography-based three-dimensional (3D) printing technology. Here, we transformed NR to photosensitive NR (PNR) by incorporating acrylate groups via chemical modifications. The acrylated NR was blended with a commercial resin (CR) at various rubber contents (0 to 3 wt %) by a simple mixing approach. The blended resin was solidified to pattern the desired specimen using a digital light processing-based 3D printer. The effect of PNR contents on mechanical properties and thermal performance of the printed specimen compared to the neat CR was studied in this work. A printed sample containing 1.5 wt % PNR can increase the elongation ability and impact strength by approximately 59 and 116%, respectively, compared to the neat CR. The microstructure of the printed objects shows a heterogeneous surface consisting of dispersed rubber droplets and a continuous CR matrix. Two glass transition temperatures belonging to the rubber phase and the resin matrix can be observed. The thermal decomposition of the printed part decreased slightly with the elevation in the rubber content. Consequently, the synthesized photosensitive natural rubber could be used as a toughness modifier employed in ultraviolet-curable resin for the light-based 3D printing technology.

3D printing of lignin: Challenges, opportunities and roads onward

As the second most abundant biopolymer on earth, and as a resource recently becoming more available in separated and purified form on an industrial scale due to the development of new isolation technologies, lignin has a key role to play in transitioning our material industry towards sustainability. Additive manufacturing (AM), the most efficient-material processing technology to date, has likewise made great strides to promote sustainable industrial solutions to our needs in engineered products. Bringing lignin research to AM has prompted the emergence of the nascent "lignin 3D printing" field. This review presents the recent state of art of this promising field and highlights its challenges and opportunities. Following a review of the industrial availability, molecular attributes, and associated properties of technical lignins, we review R&D efforts at implementing lignin systems in extrusion-based and stereolithography (SLA) printing technologies. Doing so underlines the adage of lignin research that "all lignins are not created equal," and stresses the opportunity nested in this chemical diversity created mostly by differences in isolation conditions to molecularly select and tune the attributes of technical lignin systems towards desirable properties, be it by modification or polymer blending. Considering the AM design process in its entirety, we finally propose onward routes to bring the full potential to this emerging field. We hope that this review can help promote the unique value and overdue industrial role of lignin in sustainable engineered materials and products.

UV-Curable Bio-Based Polymers Derived from Industrial Pulp and Paper Processes

Bio-based monomers represent the future market for polymer chemistry, since the political economics of different states promote green ventures toward more sustainable materials and processes. Industrial pulp and paper processing represent a large market that could advance the use of by-products to avoid waste production and reduce pollution. Lignin represents the most available side product that can be used to produce a bio-based monomer. This review is concentrated on the possibility of using bio-based monomer derivates from pulp and the paper industry for UV-curing processing. UV-curing represents the new frontier for thermoset production, allowing a fast reaction cure, less energy demand, and the elimination of solvent. The growing demand for new monomers increases research in the environmental field to substitute for petroleum-based products. This review provides an overview of the main monomers and relative families of compounds derived from industrial processes that are suitable for UV-curing. Particular focus is given to the developments reached in the last few years concerning lignin, rosin and terpenes and the related possible applications of these in UV-curing chemistry.

UV-Light Curing of 3D Printing Inks from Vegetable Oils for Stereolithography

Typical resins for UV-assisted additive manufacturing (AM) are prepared from petroleum-based materials and therefore do not contribute to the growing AM industry trend of converting to sustainable bio-based materials. To satisfy society and industry's demand for sustainability, renewable feedstocks must be explored; unfortunately, there are not many options that are applicable to photopolymerization. Nevertheless, some vegetable oils can be modified to be suitable for UV-assisted AM technologies. In this work, extended study, through FTIR and photorheology measurements, of the UV-curing of epoxidized acrylate from soybean oil (AESO)-based formulations has been performed to better understand the photopolymerization process. The study demonstrates that the addition of appropriate functional comonomers like trimethylolpropane triacrylate (TMPTA) and the adjusting of the concentration of photoinitiator from 1% to 7% decrease the needed UV-irradiation time by up to 25%. Under optimized conditions, the optimal curing time was about 4 s, leading to a double bond conversion rate (DBC%) up to 80% and higher crosslinking density determined by the Flory-Rehner empirical approach. Thermal and mechanical properties were also investigated via TGA and DMA measurements that showed significant improvements of mechanical performances for all formulations. The properties were improved further upon the addition of the reactive diluents. After the thorough investigations, the prepared vegetable oil-based resin ink formulations containing reactive diluents were deemed suitable inks for UV-assisted AM, giving their appropriate viscosity. The validation was done by printing different objects with complex structures using a laser based stereolithography apparatus (SLA) printer.

Exceptional Mechanical Properties and Heat Resistance of Photocurable Bismaleimide Ink for 3D Printing

Photosensitive resins used in three-dimensional (3D) printing are characterized by high forming precision and fast processing speed; however, they often possess poor mechanical properties and heat resistance. In this study, we report a photocurable bismaleimide ink with excellent comprehensive performance for stereolithography (SLA) 3D printing. First, the main chain of bismaleimide with an amino group (BDM) was synthesized, and then, the glycidyl methacrylate was grafted to the amino group to obtain the bismaleimide oligomer with an unsaturated double bond. The oligomers were combined with reaction diluents and photo-initiators to form photocurable inks that can be used for SLA 3D printing. The viscosity and curing behavior of the inks were studied, and the mechanical properties and heat resistance were tested. The tensile strength of 3D-printed samples based on BDM inks could reach 72.6 MPa (166% of that of commercial inks), glass transition temperature could reach 155 °C (205% of that of commercial inks), and energy storage modulus was 3625 MPa at 35 °C (327% of that of commercial inks). The maximum values of T_-5%, T_-50%, and T_max of the 3D samples printed by BDM inks reached 351.5, 449.6, and 451.9 °C, respectively. These photocured BDM inks can be used to produce complex structural components and models with excellent mechanical and thermal properties, such as car parts, building models, and pipes.

Additive Manufacture of Dynamic Thiol-ene Networks Incorporating Anhydride-Derived Reversible Thioester Links

A photoprintable dynamic thiol-ene resin was developed based on commercially available anhydride, thiol, and ene monomers. The dynamic chemistry chosen for this study relied on the thermal reversibility of the in situ generated thioester-anhydride links. The resin's rheological and curing properties were optimized to enable 3D printing using the masked stereolithography (MSLA) technique. To achieve a desirable depth of cure of 200 μm, a combination of radical photoinitiator (BAPO) and inhibitor (pyrogallol) were used at a weight ratio of 0.5 to 0.05, resulting in more than 90% thiol-ene conversion within 12 s curing time. In a series of stress relaxation and creep experiments, the dynamic reversible exchange was characterized and yielded rapid exchange rates ranging from minutes to seconds at temperatures of 80-140 °C. Little to no exchange was observed at temperatures below 60 °C. Various 3D geometries were 3D printed, and the printed objects were shown to be reconfigurable above 80 °C and depolymerizable at or above 120 °C. By deactivation of the exchange catalyst (DMAP), the stimuli responsiveness was demonstrated to be erasable, allowing for a significant shift in the actuation threshold. These highly enabling features of the dynamic chemistry open up new possibilities in the field of shape memory and 4D printable functional materials.

Reflection on the Matyjaszewski Lab Webinar Series and the Rise of Webinars in Polymer Chemistry

Webinar series are helping our community of polymer scientists to stay engaged and connected, despite the cancellation of in-person meetings and the periodic closure of laboratories to contain the spread of the coronavirus pandemic. The sustainable and inclusive character of these virtual events make them valuable learning and networking opportunities. As organizers of the Matyjaszewski Lab Webinar Series, we share herein our experience, highlighting the benefits of virtual meetings and providing a short guide for webinar organizers. Researchers, particularly young scientists, are encouraged to organize such virtual events to broaden their skills and strengthen their professional network.

Recent developments towards performance-enhancing lignin-based polymers

This review examines recent strategies, challenges, and future opportunities in preparing high-performance polymeric materials from lignin and its derivable compounds.

Cell-Laden Gelatin Methacryloyl Bioink for the Fabrication of Z-Stacked Hydrogel Scaffolds for Tissue Engineering

Hydrogel-based scaffolds have been widely used to fabricate artificial tissues capable of replacing tissues and organs. However, several challenges inherent in fabricating tissues of large size and complex morphology using such scaffolds while ensuring cell viability remain. To address this problem, we synthesized gelatin methacryloyl (GelMA) based bioink with cells for fabricating a scaffold with superior characteristics. The bioink was grafted onto a Z-stacking bioprinter that maintained the cells at physiological temperature during the printing process, without exerting any physical pressure on the cells. Various parameters, such as the bioink composition and light exposure time, were optimized. The printing accuracy of the scaffolds was evaluated using photorheological studies. The internal morphology of the scaffolds at different time points was analyzed using electron microscopy. The Z-stacked scaffolds were fabricated using high-speed printing, with the conditions optimized to achieve high model reproducibility. Stable adhesion and high proliferation of cells encapsulated within the scaffold were confirmed. We introduced various strategies to improve the accuracy and reproducibility of Z-stack GelMA bioprinting while ensuring that the scaffolds facilitated cell adhesion, encapsulation, and proliferation. Our results demonstrate the potential of the present method for various applications in tissue engineering.

Sustainable Photopolymers in 3D Printing: A Review on Biobased, Biodegradable, and Recyclable Alternatives

The global market for 3D printing materials has grown exponentially in the last decade. Today, photopolymers claim almost half of the material sales worldwide. The lack of sustainable resins, applicable in vat photopolymerization that can compete with commercial materials, however, limits the widespread adoption of this technology. The development of "green" alternatives is of great importance in order to reduce the environmental impact of additive manufacturing. This paper reviews the recent evolutions in the field of sustainable photopolymers for 3D printing. It highlights the synthesis and application of biobased resin components, such as photocurable monomers and oligomers, as well as reinforcing agents derived from natural resources. In addition, the design of biologically degradable and recyclable thermoset products in vat photopolymerization is discussed. Together, those strategies will promote the accurate and waste-free production of a new generation of 3D materials for a sustainable plastics economy in the near future.

A Bio-Based Resin for a Multi-Scale Optical 3D Printing

Materials obtained from renewable sources are emerging to replace the starting materials of petroleum-derived plastics. They offer easy processing, fulfill technological, functional and durability requirements at the same time ensuring increased bio-compatibility, recycling, and eventually lower cost. On the other hand, optical 3D printing (O3DP) is a rapid prototyping tool (and an additive manufacturing technique) being developed as a choice for efficient and low waste production method, yet currently associated with mainly petroleum-derived resins. Here we employ a single bio-based resin derived from soy beans, suitable for O3DP in the scales from nano- to macro-dimensions, which can be processed even without the addition of photoinitiator. The approach is validated using both state-of-the art laser nanolithography setup as well as a widespread table-top 3D printer - sub-micrometer accuracy 3D objects are fabricated reproducibly. Additionally, chess-like figures are made in an industrial line commercially delivering small batch production services. Such concept is believed to make a breakthrough in rapid prototyping by switching the focus of O3DP to bio-based resins instead of being restricted to conventional petroleum-derived photopolymers.

100th Anniversary of Macromolecular Science Viewpoint: Macromolecular Materials for Additive Manufacturing

Additive manufacturing (AM) has drawn tremendous attention as a versatile platform for the on-demand fabrication of objects with excellent spatial control of chemical compositions and complex architectures. The development of materials that are specifically designed for AM is highly desirable for a variety of applications ranging from personal healthcare, tissue engineering, biomedical devices, self-folding origami structures, and soft robotics. Polymeric macromolecules have received increasing attention due to a wide variety of materials, the versatility for novel chemistries, and the ability to tune chemical composition and architecture. This Viewpoint highlights the development of polymeric materials for direct-ink writing and vat photopolymerization for 3D printing applications. Recent chemical innovations and polymer architectures are overviewed, which also includes recent developments in responsive and adaptive objects from AM. Polymers for biological interface and sustainability in AM are also discussed.

100th Anniversary of Macromolecular Science Viewpoint: Polymers from Lignocellulosic Biomass. Current Challenges and Future Opportunities

Sustainable polymers from lignocellulosic biomass have the potential to reduce the environmental impact of commercial plastics while also offering significant performance and cost benefits relative to petrochemical-derived macromolecules. However, most currently available biobased polymers are hampered by insufficient thermomechanical properties, low economic feasibility (e.g., high relative cost), and reduced scalability in comparison to petroleum-based incumbents. Future biobased materials must overcome these limitations to be competitive in the marketplace. Additionally, sustainability challenges at the beginning and end of the polymer lifecycle need to be addressed using green chemistry practices and improved end-of-life waste management strategies. This viewpoint provides an overview of recent developments that can mitigate many concerns with present materials and discusses key aspects of next-generation, biobased polymers derived from lignocellulosic biomass.

Vanillin Acrylate-Based Resins for Optical 3D Printing

The investigation of biobased systems as photocurable resins for optical 3D printing has attracted great attention in recent years; therefore, novel vanillin acrylate-based resins were designed and investigated. Cross-linked polymers were prepared by radical photopolymerization of vanillin derivatives (vanillin dimethacrylate and vanillin diacrylate) using ethyl(2,4,6-trimethylbenzoyl)phenylphosphinate as photoinitiator. The changes of rheological properties were examined during the curing with ultraviolet/visible irradiation to detect the influences of solvent, photoinitiator, and vanillin derivative on cross-linking rate and network formation. Vanillin diacrylate-based polymers had higher values of yield of insoluble fraction, thermal stability, and better mechanical properties in comparison to vanillin dimethacrylate-based polymers. Moreover, the vanillin diacrylate polymer film showed a significant antimicrobial effect, only a bit weaker than that of chitosan film. Thermal and mechanical properties of vanillin acrylate-based polymers were comparable with those of commercial petroleum-derived materials used in optical 3D printing. Also, vanillin diacrylate proved to be well-suited for optical printing as was demonstrated by employing direct laser writing 3D lithography and microtransfer molding techniques.

A new safranin based three-component photoinitiating system for high resolution and low shrinkage printed parts via digital light processing

Additive manufacturing or 3D printing has attracted the interest of researchers in industry and academia because of its outstanding features. In this study, a new three-component photoinitiating system (PIS) consisting of safranin O (SFH⁺), thiol derivatives and diphenyl iodonium salt was used for the free radical photopolymerization of a diacrylate monomer (SR349) in DLP 3D printing. The photoinitiating characteristics of this PIS were evaluated and advantageously compared to those of a conventional PI (TPO) by using RT-FTIR. It is shown that the proposed PIS could be used as an efficient PIS for free radical photopolymerization. In addition, the resolution and shrinkage of printed parts in the presence of this three-component PIS were measured and compared to those printed using TPO as a photoinitiator. The resolution of printed parts was determined by using SEM and profilometry techniques. In addition, photorheometry was used to evaluate the linear shrinkage of samples. Moreover, the initiating mechanism of the three-component PIS was studied by using laser flash photolysis (LFP). A photocyclic mechanism was outlined for the three-component PIS which demonstrated this mechanism would be very beneficial for DLP 3D printing.

The resolution and shrinkage of DLP 3D printed parts improve remarkably when SFH⁺/RSH/IOD⁺ is used as a photoinitiating system.

A Review on Styrene Substitutes in Thermosets and Their Composites

In recent decades, tremendous interest and technological development have been poured into thermosets and their composites. The thermosets and composites with unsaturated double bonds curing system are especially concerned due to their versatility. To further exploit such resins, reactive diluents (RDs) with unsaturated sites are usually incorporated to improve their processability and mechanical properties. Traditional RD, styrene, is a toxic volatile organic compound and one of the anticipated carcinogens warned by the National Institute of Health, USA. Most efforts have been conducted on reducing the usage of styrene in the production of thermosets and their composites, while very few works have systematically summarized these literatures. Herein, recent developments regarding styrene substitutes in thermosets and their composites are reviewed. Potential styrene alternatives, such as vinyl derivatives of benzene and (methyl)acrylates are discussed in details. Emphasis is focused on the strategies on developing novel RD monomers through grafting unsaturated functional groups on renewable feedstocks such as carbohydrates, lignin, and fatty acids. This review also highlights the development and characteristics of RD monomers and their influence on processability and mechanical performance of the resulting thermosets and composites.