A Critical Review for Synergic Kinetics and Strategies for Enhanced Photopolymerizations for 3D-Printing and Additive Manufacturing

The synergic features and enhancing strategies for various photopolymerization systems are reviewed by kinetic schemes and the associated measurements. The important topics include (i) photo crosslinking of corneas for the treatment of corneal diseases using UVA-light (365 nm) light and riboflavin as the photosensitizer; (ii) synergic effects by a dual-function enhancer in a three-initiator system; (iii) synergic effects by a three-initiator C/B/A system, with electron-transfer and oxygen-mediated energy-transfer pathways; (iv) copper-complex (G1) photoredox catalyst in G1/Iod/NVK systems for free radical (FRP) and cationic photopolymerization (CP); (v) radical-mediated thiol-ene (TE) photopolymerizations; (vi) superbase photogenerator based-catalyzed thiol-acrylate Michael (TM) addition reaction; and the combined system of TE and TM using dual wavelength; (vii) dual-wavelength (UV and blue) controlled photopolymerization confinement (PC); (viii) dual-wavelength (UV and red) selectively controlled 3D printing; and (ix) three-wavelength selectively controlled in 3D printing and additive manufacturing (AM). With minimum mathematics, we present (for the first time) the synergic features and enhancing strategies for various systems of multi-components, initiators, monomers, and under one-, two-, and three-wavelength light. Therefore, this review provides not only the bridging between modeling and measurements, but also guidance for further experimental studies and new applications in 3D printings and additive manufacturing (AM), based on the innovative concepts (kinetics/schemes).

Tailoring a hybrid three-component photoinitiating system for 3D printing

In the field of additive manufacturing DLP vat technologies are promising 3D printing techniques. The need of highly efficient photoiniating systems drives us to the development of photocyclic 3-component initiators. In order to improve the 3D printing sensitivity, we present in this paper the use of synthesized clay to tune up the photochemistry underlying the initiating radical production. Therefore, a three-component initiating system, based on a cationic dye, two coinitiators and with a clay filler suitable for DLP 3D printing of acrylate resins leading to high quality of parts and low printing time, is developed.

Onium salts improve the kinetics of photopolymerization of acrylate activated with visible light

The aim was study the influence of onium salts on the kinetics of photopolymerization in the visible light region. Trimethylolpropane triacrylate TMPTA was selected as a monomer, and activated by 1,3-bis(phenylamino)squaraine (SQ) used as a photosensitizer in addition to tetramethylammonium n-butyltriphenylborate (B2). The iodonium salt [A–I–B]⁺X⁻ functioned as a second radical initiator, bearing a different substitution pattern for the cation. The ternary system was formulated with different concentrations of both borate and diphenyliodonium salts. Differential scanning calorimetry was used to investigate the polymerization reaction over the photoactivation time carried out at 300 nm < λ < 500 nm irradiation. When the squaraine dye/borate salt was used as photoinitiator, a slow polymerization reaction was observed and a lower monomer conversion. The addition of a third component (onium salt) increased the polymerization rate and conversion. Ternary photoinitiator systems showed improvement in the polymerization rate of triacrylate leading to high conversion in a short photoactivation time. The photoinitiating ability of bi- and tri-component photoinitiators acting in the UV-Vis region for initiation polymerization of triacrylate was compared with those of some commercially used photoinitiating systems. It was also found, that, the parallel electron transfer from an excited state of the sensitizer to [A–I–B]⁺X⁻, and an electron transfer from a ground state of R(Ph)₃B⁻N(CH₃)₄⁺ to an excited state of the sensitizer results in two types of initiating radical.

The chemical mechanisms were investigated by steady state photolysis and nanosecond laser flash photolysis experiments. A mechanism for initiating polymerization using both onium salts is proposed here.

Highly Effective Sensitizers Based on Merocyanine Dyes for Visible Light Initiated Radical Polymerization

The 5-(4-substituted-arylidene)-1,3-dimethylpyrimidine-2,4,6-triones were tested as visible light sensitizers for phenyltrialkylborate salts applied to initiate polymerization processes. The initiation occurs as a result of photoinduced electron transfer from the borate salt to the merocyanine dye. The main factor that facilitates the step of the reaction is the free energy change for electron transfer. Its value is favorable according to the reduction properties of the dyes influenced by the type of amino groups and the oxidation potentials of the borate salts. The observed bleaching of the dyes during photopolymerization affects the yield of both the alkyl radical and sensitizer-based radical formation and thus the efficiency of the photopolymerization.

Photoinitiators derived from natural product scaffolds: monochalcones in three-component photoinitiating systems and their applications in 3D printing

Design of new photoinitiators based on natural Chalcone scaffold.

The photooxidative sensitization of bis(p-substituted diphenyl)iodonium salts in the radical polymerization of acrylates

The ability of two-component dyeing photoinitiating systems for the radical polymerization of 1,6-hexanediol diacrylate (HDDA) and 2-ethyl-2-(hydroxymethyl)-1,3-propanediol triacrylate (TMPTA) is presented. The systems under study comprised a hemicyanine dye as a sensitizer and iodonium salts that played a role of a coinitiator. The kinetic parameters of the polymerization reaction, such as the rate of polymerization (R_p) and the degree of conversion of monomer (C_%), were estimated. The thermodynamic feasibility of an electron transfer process in the systems studied was verified and calculated using the Rehm–Weller equation. It was found that a benzoxazole derivative in the presence of iodonium salts effectively initiated the polymerization of acrylate monomers. The polymerization rates of about 10⁻⁷ s⁻¹ and the degree of conversion of acrylate groups from 20% to 50% were observed. The effects of photoinitiator structures on the initiating ability and spectroscopic properties of sensitizers are described in this article.

The ability of two-component dyeing photoinitiating systems for the radical polymerization of 1,6-hexanediol diacrylate (HDDA) and 2-ethyl-2-(hydroxymethyl)-1,3-propanediol triacrylate (TMPTA) is presented.

Photocatalysis in organic and polymer synthesis

This review, with over 600 references, summarizes the recent applications of photoredox catalysis for organic transformation and polymer synthesis. Photoredox catalysts are metallo- or organo-compounds capable of absorbing visible light, resulting in an excited state species. This excited state species can donate or accept an electron from other substrates to mediate redox reactions at ambient temperature with high atom efficiency. These catalysts have been successfully implemented for the discovery of novel organic reactions and synthesis of added-value chemicals with an excellent control of selectivity and stereo-regularity. More recently, such catalysts have been implemented by polymer chemists to post-modify polymers in high yields, as well as to effectively catalyze reversible deactivation radical polymerizations and living polymerizations. These catalysts create new approaches for advanced organic transformation and polymer synthesis. The objective of this review is to give an overview of this emerging field to organic and polymer chemists as well as materials scientists.

Isomerization controlled photopolymerization: effect of dye photophysics on photoinitiation efficiency

The efficiency of free radical polymerization by photoinitiating systems based on two Astrazon orange cyanine dyes was shown to be directly related to the isomerization process of the dye in the excited states. The impact of resin viscosity on photopolymerization reactions was measured and related to the overall radical quantum yields. The quantum yields were calculated according to the photocyclic behaviour of the initiating systems based on the Astrazon orange dyes. These dyes are characterized by a viscosity dependent photophysics, which leads to an isomerization-diffusion-controlled photopolymerization. Besides this demonstration, Astrazon orange dyes appeared to be very good candidates for free radical photopolymerization in the visible, presenting high absorption coefficient, low cost and good sensitivity.

Fluorescent Brighteners as Visible LED-Light Sensitive Photoinitiators for Free Radical Photopolymerizations

The photochemical and electrochemical investigations of commercially available, safe, and cheap fluorescent brighteners, namely, triazinylstilbene (commercial name: fluorescent brightener 28) and 2,5-bis(5-tert-butyl-benzoxazol-2-yl)thiophene, as well as their original use as photoinitiators of polymerization upon light emitting diode (LED) irradiation are reported. Remarkably, their excellent near-UV-visible absorption properties combined with outstanding fluorescent properties allow them to act as high-performance photoinitiators when used in combination with diaryliodonium salt. These two-component photoinitiating systems can be employed for free radical polymerizations of acrylate. In addition, this brightener-initiated photopolymerization is able to overcome oxygen inhibition even upon irradiation with low LED light intensity. The underlying photochemical mechanisms are investigated by electron-spin resonance-spin trapping, fluorescence, cyclic voltammetry, and steady-state photolysis techniques.

New role of aminothiazonaphthalimide derivatives: outstanding photoinitiators for cationic and radical photopolymerizations under visible LEDs

Aminothiazonaphthalimide derivatives can act as photoinitiators (when combined with additives) to start the cationic polymerization or the radical polymerization upon exposure to visible LEDs or a polychromatic visible light.

Optimization of a Safranine O three-component photoinitiating system for use in holographic recording

The coupling between a holographic resin, combining multiple monomers and additives, with photoinitiating systems (PIS) is not straightforward. In this paper, a classic PIS based on Safranine O (SFH+) as dye, an amine (ethyl-4-(dimethylamino)benzoate) as electron donor, and a triazine derivative (2-(4-methoxyphenyl)-4,6-bis(trichloromethyl)-1,3,5-triazine) as electron acceptor for holographic recording was studied using time-resolved spectroscopic experiments. By taking into account the viscosity of the matrix, a method to evaluate the overall quantum yield of radicals released is proposed and the contribution of singlet and triplet excited states of SFH+ in the formation of radicals is evaluated. Then the corresponding photopolymerization efficiencies of the PIS, studied by real-time FTIR, are compared with holographic recording experiments: this system allows the formation of a hologram with high diffraction efficiency (0.9) in 3 s of irradiation time. It is shown that besides holographic resin formulation, the photochemistry of PIS also impacts the hologram formation.

Enhanced visible radiation photopolymerization of dimethacrylates with the three component thioxanthone (CPTXO)–amine–iodonium salt system

The three component thioxanthone/iodonium/amine visible light photoinitiator system is four times more efficient due to irreversible oxidation of the ketyl and the amine radicals by the iodonium salt and the regeneration of the thioxanthone and produce twice as many active radicals.

Tailoring of organic dyes with oxidoreductive compounds to obtain photocyclic radical generator systems exhibiting photocatalytic behavior

The combination of a dye which absorbs the photon, an electron acceptor and an electron donor leading to energy conversion through electron transfer, was the basis of the so called three-component systems. In this paper, an experimental work combining Rose bengal dye with a triazine derivative as electron acceptor and ethyl 4-(dimethylamino)benzoate as electron donor, will underline the benefit of the photocyclic behavior of three-component systems leading to the dye regeneration. A thermodynamic approach of the photocycle is presented, followed by a mechanistic and computational study of ideal photocycles, in order to outline the specific kinetics occuring in so called photocatalytic systems. The simple kinetic model used is enough to outline the benefit of the cyclic system and to give the basic requirements in term of chemical combination needed to be fulfilled in order to obtain a photocatalytic behavior.

Photopolymerization of methyl methacrylate: effects of photochemical and photonic parameters on the chain length

The effects of photochemical and photonic parameters are investigated on the chain length of poly(methylmethacrylate) (PMMA) as formed by the free radical photopolymerization process.

Red-light-induced cationic photopolymerization: perylene derivatives as efficient photoinitiators

Nine different perylene derivatives are prepared and their ability to initiate, when combined with an iodonium salt (and optionally N-vinylcarbazole), a ring-opening cationic photopolymerization of epoxides under very soft halogen lamp irradiation is investigated. One of them is particularly efficient under a red laser diode exposure at 635 nm and belongs now to the very few systems available at this wavelength. The photochemical mechanisms are studied by steady-state photolysis, electron spin resonance spin trapping, fluorescence, cyclic voltammetry, and laser flash photolysis techniques.