Rapid formation of regulated methacrylate networks yielding tough materials for lithography-based 3D printing (original) (raw)
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Angewandte Chemie (International ed. in English), 2018
The formation of networks through light-initiated radical polymerization allows little freedom for tailored network design. The resulting inhomogeneous network architectures and brittle material behavior of such glassy-type networks limit the commercial application of photopolymers in 3D printing, biomedicine, and microelectronics. An ester-activated vinyl sulfonate ester (EVS) is presented for the rapid formation of tailored methacrylate-based networks. The chain transfer step induced by EVS reduces the kinetic chain length of the photopolymer, thus shifting the gel point to higher conversion, which results in reduced shrinkage stress and higher overall conversion. The resulting, more homogeneous network is responsible for the high toughness of the material. The unique property of EVS to promote nearly retardation-free polymerization can be attributed to the fact that after the transfer step no polymerizable double bond is formed, as is usually seen in classical chain transfer agen...
Polymer, 2018
Chain transfer reagents serve as a valuable tool for the modification of methacrylate-based photopolymer networks. Employment of such chemistry enables easy tuning of mechanical and thermomechanical network properties, thus potentially widens the field of application for such crosslinked polymer networks. Thiols are the most prominent class of chain transfer reagent and possess a great number of favorable characteristics (e.g., high conversion, reduced shrinkage stress, or high toughness, meaning the combination of high tensile strength and impact resistance). Mostly, thiols with higher functionality are used for network formation as monomer leaching and thinning effects are crucial drawbacks of monofunctional additives. Addition fragmentation chain transfer (AFCT) reagents (e.g., vinyl sulfonate esters) have been recently introduced as powerful network regulators for methacrylate-based photopolymerization. After successful synthesis of a difunctional vinyl sulfonate ester the photoreactivity in methacrylate-based systems was compared to an equivalent thiol-ene system. Through the introduction of a difunctional vinyl sulfonate ester-derivative, homogeneous photopolymer networks with high conversions, reduced shrinkage stress, tunable crosslink density and thermomechanical properties were fabricated. The final materials exhibit high hardness, tensile strength and gel content as well as improved impact resistance.
Polymers
Additive manufacturing (3D printing) has significantly changed the prototyping process in terms of technology, construction, materials, and their multiphysical properties. Among the most popular 3D printing techniques is vat photopolymerization, in which ultraviolet (UV) light is deployed to form chains between molecules of liquid light-curable resin, crosslink them, and as a result, solidify the resin. In this manuscript, three photopolymerization technologies, namely, stereolithography (SLA), digital light processing (DLP), and continuous digital light processing (CDLP), are reviewed. Additionally, the after-cured mechanical properties of light-curable resin materials are listed, along with a number of case studies showing their applications in practice. The manuscript aims at providing an overview and future trend of the photopolymerization technology to inspire the readers to engage in further research in this field, especially regarding developing new materials and mathematical...
3D Printing Amorphous Polysiloxane Terpolymers via Vat Photopolymerization
Macromolecular Chemistry and Physics, 2019
Photocuring and vat photopolymerization (VP) additive manufacturing (AM) is reported for two families of fully amorphous poly(dimethyl siloxane) (PDMS) terpolymers containing either diphenylsiloxy (DiPhS) or diethylsiloxy (DiEtS) repeating units. A thiol-functionalized PDMS crosslinker enables rapid crosslinking in air using efficient thiol-ene addition. Differential scanning calorimetry and dynamic mechanical analysis (DMA) confirm the absence of crystallinity for the DiPhS-containing systems, while DMA shows a rubbery plateau extending to greater than 200 °C for the DiEtS-containing system. VP-AM of both photopolymer systems afford well-defined 3D geometries, including high aspect ratio structures, which demonstrate feasibility of these photopolymers for the 3D printing of unique geometric objects that require elastomeric performance to temperatures as low as −120 °C.
Photopolymer Resins with Biobased Methacrylates Based on Soybean Oil for Stereolithography
ACS Applied Polymer Materials, 2020
The accessibility of renewable materials that are both sustainable and competitive is essential to accommodate the rapid growth in consumption of 3D printing materials. We have developed biobased photopolymer resins based on modified soybean oil for application in commercial stereolithography printers. First, soybean oil methacrylates with various functionalities were successfully synthesized from epoxidized soybean oil as an alternative to commercially available soybean oil acrylate. A library of photoresins was created by mixing up to 80% of the biobased (meth)acrylate oligomers with biobased diluents and a photoinitiator. The resin composition was optimized to achieve a maximum biobased content and a low viscosity. The manufactured parts demonstrated complete layer fusion and accurate print quality. Stiffness and toughness can be tuned by altering the chemical composition or the number of functional groups per oligomer. These biobased materials can be employed to reduce the environmental impact of additive manufacturing while being competitive with current fossil-based resins from commercial manufacturers.
Materials
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 E...
Drug Delivery and Translational Research
Vat photopolymerisation (VP) three-dimensional printing (3DP) has attracted great attention in many different fields, such as electronics, pharmaceuticals, biomedical devices and tissue engineering. Due to the low availability of biocompatible photocurable resins, its application in the healthcare sector is still limited. In this work, we formulate photocurable resins based on urethane dimethacrylate (UDMA) combined with three different difunctional methacrylic diluents named ethylene glycol dimethacrylate (EGDMA), di(ethylene glycol) dimethacrylate (DEGDMA) or tri(ethylene glycol) dimethacrylate (TEGDMA). The resins were tested for viscosity, thermal behaviour and printability. After printing, the 3D printed specimens were measured with a digital calliper in order to investigate their accuracy to the digital model and tested with FT-IR, TGA and DSC. Their mechanical properties, contact angle, water sorption and biocompatibility were also evaluated. The photopolymerizable formulatio...
Catalysts
In this work, we presented a new bimolecular photoinitiating system based on 2-amino-4,6-diphenylpyridine-3-carbonitrile derivatives as visible photosensitizers of diphenyliodonium salt. Real-time FTIR and photo-DSC photopolymerization experiments with a cycloaliphatic epoxide and vinyl monomers showed surprisingly good reactivity of the bimolecular photoinitiating systems under UV-A, as well as under visible light sources. Steady-state photolysis, fluorescence experiments, theoretical calculations of molecular orbitals, and electrochemical analysis demonstrated photo-redox behavior as well as the ability to form initiating species via photo-reduction or photo-oxidation pathways, respectively. Therefore, the 2-amino-4,6-diphenylpyridine-3-carbonitrile derivatives were also investigated as a type II free-radical photoinitiator with amine. It was confirmed that the 2-amino-4,6-diphenylpyridine-3-carbonitrile derivatives, in combination with different types of additives, e.g., amine as...