3D Printing and <em>In Situ</em> Surface Modification <em>via</em> Type I Photoinitiated Reversible Addition-Fragmentation Chain Transfer Polymerization

3D printing provides facile access to geometrically complex materials. However, these materials have intrinsically linked bulk and interfacial properties ...

University of New South Wales

Copper-Mediated Living Radical Polymerization (Atom Transfer Radical Polymerization and Copper(0) Mediated Polymerization): From Fundamentals to Bioapplications.

By examining structurally similar halogenated xanthene dyes, this study establishes a guiding principle for resolving structure-property- performance relationships in the photocontrolled PET-RAFT polymerization system (PET-RAFT: photoinduced electron/energy transfer-reversible addition-fragmentation chain transfer). We investigated the effect of the halogen substituents on the photophysical and electrochemical properties of the xanthene dyes acting as photocatalysts and their resultant effect on the performance of PET-RAFT polymerization. Consideration of the structure- property-performance relationships allowed design of a new xanthene photocatalyst, where its photocatalytic activity (oxygen tolerance and polymerization rate) was successfully optimized for PET-RAFT polymerization. We expect that this study will serve as a theoretical framework in broadly guiding the design of high performance photocatalysts for organic photocatalysis.

Guiding the Design of Organic Photocatalyst for PET-RAFT Polymerization: Halogenated Xanthene Dyes.

Reversible addition-fragmentation chain-transfer (RAFT) polymerization is a valuable tool for synthesizing macromolecules with controlled topologies and diverse chemical functionalities. However, the application of RAFT polymerization to additive-manufacturing processes has been prevented due to the slow polymerization rates of typical systems. In this work, we developed and optimized a rapid visible (green) light mediated RAFT polymerization process and applied it to an open-air 3D printing system. The reaction components are non-toxic, metal free and environmentally friendly, which tailors these systems toward biomaterial fabrication. The inclusion of RAFT agent in the photosensitive resin provided control over the mechanical properties of 3D printed materials and allowed these materials to be post-functionalized after 3D printing. Additionally, photoinduced spatiotemporal control of the network structure provided a one-pass approach to 4D printed materials. This RAFT-mediated 3D and 4D printing process should provide access to a range of new functional and stimuli-responsive materials.

A Versatile 3D and 4D Printing System through Photocontrolled RAFT Polymerization.

Recent achievements and future opportunities for the design of 2D, 3D, and 4D materials using photochemical reactions are summarized. Light is an attractive stimulus for material design due to its outstanding spatiotemporal control, and its ability to mediate rapid polymerization under moderate reaction temperatures. These features have been significantly enhanced by major advances in light generation/manipulation with light-emitting diodes and optical fiber technologies which now allows for a broad range of cost-effective fabrication protocols. This combination is driving the preparation of sophisticated 2D, 3D, and 4D materials at the nano-, micro-, and macrosize scales. Looking ahead, future challenges and opportunities that will significantly impact the field and help shape the future of light as a versatile and tunable design tool are highlighted.

Designing with Light: Advanced 2D, 3D, and 4D Materials.

In this study, porphyrinic zirconium (Zr) MOFs were investigated as heterogeneous photocatalysts for photoinduced electron transfer-reversible addition-fragmentation chain transfer (PET-RAFT) polymerization of various monomers under a broad range of wavelengths, producing polymers with high monomer conversions, narrow molecular weight distributions, low dispersity and good chain-end fidelity. Screening of various porphyrinic Zr-MOFs (Zn) containing Zn-metalled porphyrinic ligands demonstrated that MOF-525 (Zn) with the smallest size had the best photocatalytic activity in PET-RAFT polymerization, due to enhanced dispersion and light penetration. Oxygen tolerance and temporal control were also demonstrated during MOF catalysed PET-RAFT. Results suggested that the polymerization rates were significantly affected by changing the size and surface area of MOFs, and the heterogeneous MOF photocatalysts could be easily separated and recycled for up to five independent PET-RAFT polymerizations without an obvious decrease in efficiency. Finally, the MOF photocatalysts were utilized to create three-dimensional polymeric objects with high resolution via visible light mediated stereolithography in an open-air environment.

Porphyrinic Zirconium Metal-Organic Frameworks (MOFs) as Heterogeneous Photocatalysts for PET-RAFT Polymerization and Stereolithography.

RAFT facilitated digital light projection 3D printing of polymeric materials provides a convenient and facile route for inducing post-fabrication transformations via reactivation of dormant chain transfer agents. In this work, we report the use of a Norrish type I photoinitiator in conjunction with a RAFT agent to produce a variety of open-air 3D printable resins that rapidly cure under visible light irradiation. The photoinitiator-RAFT system polymerizes extremely quickly and provides high 3D printing build rates of up to 9.1 cm h , representing a 7-fold increase compared to previous RAFT mediated 3D printing systems. 3D printed materials containing thiocarbonylthio groups can be also produced using low concentrations of divinyl comonomers in the initial resins, which has not been successfully achieved using other photocontrolled RAFT polymerization techniques. Interestingly, the inclusion of RAFT agents significantly improves 3D printing resolution compared to formulations without RAFT agent, allowing the fabrication of intricate and complex objects. Spatiotemporally controlled surface modifications of the 3D printed objects from the dormant RAFT agent groups on the material surfaces were also performed under one and two-pass configurations, inducing multiple successive post-printing transformations on the same object.

Rapid High-Resolution 3D Printing and Surface Functionalization via Type I Photoinitiated RAFT Polymerization.

A series of poly(N-isopropylacrylamide) (PNIPAm) homopolymers with narrow molecular weight distributions (MWDs) is prepared via photoinduced electron/energy transfer-reversible addition-fragmentation chain transfer (PET-RAFT) polymerization. The thermal transition temperature of these polymer samples is analyzed via turbidity measurements in water/N,N'-dimethylformamide mixtures, which show that the cloud point temperatures are inversely proportional to the weight average molecular weight (M ). Binary mixtures of the narrowly distributed PNIPAm samples are also prepared and the statistical parameters for the MWDs of these blends are determined. Very interestingly, for binary blends of the PNIPAm samples, the thermoresponsive transition is not only dependent on the M , which has been shown previously, but also on higher order statistical parameters of the MWDs. Specifically, at very high values of skewness and kurtosis, the polymer blends deviate from a single sharp thermoresponsive transition toward a broader thermal response, and eventually to a regime of two more distinct transitions. This work highlights the importance of in-depth characterization of polymer MWDs for thermoresponsive polymers.

Influence of Molecular Weight Distribution on the Thermoresponsive Transition of Poly(N-isopropylacrylamide).

Ultrathin porphyrinic 2D MOFs, ZnTCPP nanosheets (TCPP: 5,10,15,20-(tetra-4-carboxyphenyl) porphyrin) were employed as heterogeneous photocatalysts to activate PET-RAFT polymerization under various wavelengths ranging from violet to orange light. High polymerization rates, oxygen tolerance, and precise temporal control were achieved. The polymers showed narrow molecular weight distributions and good chain-end fidelity. The 2D ZnTCPP nanosheets were applied as photocatalysts in stereolithographic 3D printing in an open-air environment under blue light to yield well-defined 3D printed objects. Apart from providing an efficient catalytic system, 2D ZnTCPP nanosheets reinforced the mechanical properties of the 3D printed materials. The presence of ZnTCPP embedded in the materials conferred effective antimicrobial activity under visible light by production of singlet oxygen, affording 98 % and 93 % anti-bacterial efficiency against Gram-positive and Gram-negative bacteria, respectively.

2D Porphyrinic Metal-Organic Framework Nanosheets as Multidimensional Photocatalysts for Functional Materials.

Synthetic polymers are omnipresent in society as textiles and packaging materials, in construction and medicine, among many other important applications. Alternatively, natural polymers play a crucial role in sustaining life and allowing organisms to adapt to their environments by performing key biological functions such as molecular recognition and transmission of genetic information. In general, the synthetic and natural polymer worlds are completely separated due to the inability for synthetic polymers to perform specific biological functions; in some cases, synthetic polymers cause uncontrolled and unwanted biological responses. However, owing to the advancement of synthetic polymerization techniques in recent years, new synthetic polymers have emerged that provide specific biological functions such as targeted molecular recognition of peptides, or present antiviral, anticancer, and antimicrobial activities. In this review, the emergence of this generation of bioactive synthetic polymers and their bioapplications are summarized. Finally, the future opportunities in this area are discussed.

Bioactive Synthetic Polymers.

Currently, there are no straightforward methods to 3D print materials with nanoscale control over morphological and functional properties. Here, a novel approach for the fabrication of materials with controlled nanoscale morphologies using a rapid and commercially available Digital Light Processing 3D printing technique is demonstrated. This process exploits reversible deactivation radical polymerization to control the in-situ-polymerization-induced microphase separation of 3D printing resins, which provides materials with complex architectures controllable from the macro- to nanoscale, resulting in the preparation of materials with enhanced mechanical properties. This method does not require specialized equipment or process conditions and thus represents an important development in the production of advanced materials via additive manufacturing.

Nanostructure Control in 3D Printed Materials.

Vat photopolymerization-based 3D printing techniques have been widely used to produce high-resolution 3D thermosetting materials. However, the lack of repairability of these thermosets leads to the production of waste. In this study, reversible addition fragmentation chain transfer (RAFT) agents are incorporated into resin formulations to allow visible light (405 nm) mediated 3D printing of materials with self-healing capabilities. The self-healing process is based on the reactivation of RAFT agent embedded in the thermosets under UV light (365 nm), which enables reformation of the polymeric network. The self-healing process can be performed at room temperature without prior deoxygenation. The impact of the type and concentration of RAFT agents in the polymer network on the healing efficiency is explored. Resins containing RAFT agents enable 3D printing of thermosets with self-healing properties, broadening the scope of future applications for polymeric thermosets in various fields.

Nathaniel Corrigan

Cluster for Advanced Macromolecular Design,
and Australian Centre for Nanomedicine,
School of Chemical Engineering,
Cluster for Advanced Macromolecular Design, and Australian Centre for Nanomedicine, School of Chemical Engineering

University of New South Wales

3D Printing and In Situ Surface Modification via Type I Photoinitiated Reversible Addition-Fragmentation Chain Transfer Polymerization