Neue Hochleistungs‐LEDs ermöglichen Photochemie für die Nahinfrarot‐sensibilisierte radikalische und kationische Photopolymerisation

"Invisible" Digital Light Processing 3D Printing with Near Infrared Light

The ability to 3D print structures with low-intensity, long-wavelength light will broaden the materials scope to facilitate inclusion of biological components and nanoparticles. Current materials limitations arise from the pervasive absorption, scattering, and/or degradation that occurs upon exposure to high-intensity, short-wavelength (ultraviolet) light, which is the present-day standard used in light-based 3D printers. State-of-the-art techniques have recently extended printability to orange/red light. However, as the wavelength of light increases, so do the inherent challenges to match the speed and resolution of traditional UV light-induced solidification processes (i.e., photocuring). Herein, a photosystem is demonstrated to enable low-intensity (<5 mW/cm2), long-wavelength (∼850 nm) near-infrared (NIR) light-driven 3D printing, "invisible" to the human eye. The combination of a NIR absorbing cyanine dye with electron-rich and -deficient redox pairs was required for rapid photocuring in a catalytic manner. The rate of polymerization and time to solidification upon exposure to NIR light were characterized via in situ spectroscopic and rheological monitoring. Translation to NIR digital light processing (projection-based) 3D printing was accomplished through rigorous optimization of resin composition and printing parameters to balance the speed (<60 s/layer) and resolution (<300 μm features). As a proof-of-concept, composite 3D printing with nanoparticle-infused resins was accomplished. Preliminary analysis showed improved feature fidelity for structures produced with NIR relative to UV light. The present report provides key insight that will inform next-generation light-based photocuring technology, such as wavelength-selective multimaterial 3D bio- and composite-printing.

Rational Selection of Cyanines to Generate Conjugate Acid and Free Radicals for Photopolymerization upon Exposure at 860 nm

Different cyanines absorbing in the NIR between 750 and 930 nm were applied to study the efficiency of both radical and cationic polymerization in combination with diaryliodonium salt. Variation of the connecting methine chain and structure of the terminal indolium moiety provided a deeper insight in the structure of the cyanine NIR‐sensitizer and the efficiency to generate initiating radicals and conjugate acid. Photophysical studies were pursued by fluorescence spectroscopy providing a deeper understanding regarding the lifetime of the excited state and contribution of nonradiative deactivation resulting in generation of additional heat in the polymerization process. Furthermore, electrochemical experiments demonstrated connection to oxidation and reduction capability as influenced by the structural pattern of the sensitizer. LC–MS measurements provided a deeper pattern about the photoproducts formed. A nonamethine‐based cyanine showed the best performance regarding bleaching in combination with an iodonium salt at 860 nm.

NIR-Sensitized Cationic and Hybrid Radical/Cationic Polymerization and Crosslinking

NIR‐sensitized cationic polymerization proceeded with good efficiency, as was demonstrated with epoxides, vinyl ether, and oxetane. A heptacyanine functioned as sensitizer while iodonium salt served as coinitiator. The anion adopts a special function in a series selected from fluorinated phosphates (a: [PF₆]⁻, b: [PF₃(C₂F₅)₃]⁻, c: [PF₃(n‐C₄F₉)₃]⁻), aluminates (d: [Al(O‐t‐C₄F₉)₄]⁻, e: [Al(O(C₃F₆)CH₃)₄]⁻), and methide [C(O‐SO₂CF₃)₃]⁻ (f). Vinyl ether showed the best cationic polymerization efficiency followed by oxetanes and oxiranes. DFT calculations provided a rough pattern regarding the electrostatic potential of each anion where d showed a better reactivity than e and b. Formation of interpenetrating polymer networks (IPNs) using trimethylpropane triacrylate and epoxides proceeded in the case of NIR‐sensitized polymerization where anion d served as counter ion in the initiator system. No IPN was formed by UV‐LED initiation using the same monomers but thioxanthone/iodonium salt as photoinitiator. Exposure was carried out with new NIR‐LED devices emitting at either 805 or 870 nm.

NIR-Sensitized Activated Photoreaction between Cyanines and Oxime Esters: Free-Radical Photopolymerization

Cyanines comprising either a benzo[e]‐ or benzo[c,d]indolium core facilitate initiation of radical photopolymerization combined with high power NIR‐LED prototypes emitting at 805 nm, 860 nm, or 870 nm, while different oxime esters function as radical coinitiators. Radical photopolymerization followed an initiation mechanism based on the participation of excited states, requiring additional thermal energy to overcome an existing intrinsic activation barrier. Heat released by nonradiative deactivation of the sensitizer favored the system, even under conditions where a thermally activated photoinduced electron transfer controls the reaction protocol. The heat generated internally by the NIR sensitizer promotes generation of the initiating reactive radicals. Sensitizers with a barbiturate group at the meso‐position preferred to bleach directly, while sensitizers carrying a cyclopentene moiety unexpectedly initiated the photosensitized mechanism.

Carbon Dots as a Promising Green Photocatalyst for Free Radical and ATRP-Based Radical Photopolymerization with Blue LEDs

Carbon dots (CDs) have been used for the first time as a sensitizer to initiate and activate free radical and controlled radical polymerization, respectively, based on an ATRP protocol with blue LEDs. Consideration of diverse heteroatom-doped CDs indicated that N-doped CDs could serve as an effective photocatalyst and photosensitizer in combination with LEDs emitting either at 405 nm or 470 nm. Free radical polymerization was initiated by combining the CDs with an iodonium or sulfonium salt in tri(propylene glycol) diacrylate. Polymerization of methyl methacrylate (MMA) by photo-induced ATRP was achieved with CDs and ethyl α-bromophenylacetate using CuII as catalyst in the ppm range. The polymers obtained showed temporal control, narrower dispersity ≲1.5, and chain-end fidelity. The first-order kinetics and ON/OFF experiments additionally gave evidence of the constant concentration of polymer radicals. No remarkable cytotoxic activity was observed for the CDs, underlining their biocompatibility.

Effective Utilization of NIR Wavelengths for Photo-Controlled Polymerization: Penetration Through Thick Barriers and Parallel Solar Syntheses

This contribution details an efficient and controlled photopolymerization regulated by far-red (λ=680 nm) and NIR (λ=780 and 850 nm) light in the presence of aluminium phthalocyanine and aluminium naphthalocyanine. Initiating radicals are generated by photosensitization of peroxides affording an effective strategy that provides controlled polymerization of a variety of monomers with excellent living characteristics. Critically, long wavelength irradiation provides penetration through thick barriers, affording unprecedented rates of controlled polymerization that can open new and exciting applications. Furthermore, a more optimized approach to performing solar syntheses is presented. By combining the narrow Q-bands of these photocatalysts with others possessing complementary absorptions, layered, independent polymerizations and organic transformations may be performed in parallel under a single broadband emission source, such as sunlight.

Photochemistry with Cyanines in the Near Infrared: A Step to Chemistry 4.0 Technologies

Cyanines covering the absorption in the near infrared (NIR) are attractive for distinct applications. They can interact either with lasers exhibiting line-shaped focus emitting at both 808 and 980 nm or bright high intensity NIR-LEDs with 805 nm emission, respectively. This is drawing attention to Industry 4.0 applications. The major deactivation occurs through a non-radiative process resulting in the release of heat into the surrounding, although a small fraction of radiative deactivation also takes place. Most of these NIR-sensitive systems possess an internal activation barrier to react in a photonic process with initiators resulting in the generation of reactive radicals and acidic cations. Thus, the heat released by the NIR absorber helps to bring the system, consisting of an NIR sensitizer and initiator, above such internal barriers. Molecular design strategies making these systems more compatible with distinct applications in a certain oleophilic surrounding are considered as a big challenge. This includes variations of the molecular pattern and counter ions derived from super acids exhibiting low coordinating properties. Further discussion focusses on the use of such systems in Chemistry 4.0 related applications. Intelligent software tools help to improve and optimize these systems combining chemistry, engineering based on high-throughput formulation screening (HTFS) technologies, and machine learning algorithms to open up novel solutions in material sciences.

Different NIR dye scaffolds for polymerization reactions under NIR light

Photopolymerization under NIR light with squarylium, squaraine, porphyrin or Bodipy dyes.