Itaconic-Acid-Based Sustainable Poly(ester amide) Resin for Stereolithography

Synthesis of Bio-Based Polyester Resins for Vat Photopolymerization 3D Printing

Driven by environmental considerations, the scientific community has directed great effort towards the synthesis of new materials derived from renewable resources. However, for photocurable resins, most commercially available building blocks still rely on petroleum-based precursors. Herein, we present a simple synthesis route for bio-based acrylate-modified polyester resins, whose viscosity is sufficiently low for processing them with vat photopolymerization 3D printing. The established synthesis route enables the gradual substitution of fossil-based raw materials with bio-based alternatives. The acid number, color and viscosity of the bio-based acrylic resins are characterized and photocurable formulations are prepared by adding a radical photoinitiator. The photopolymerization kinetics, and thermomechanical and mechanical properties of the photopolymers are investigated as a function of the resin structure and benchmarked against a commercially available petroleum-based counterpart. Finally, the processability of the new bio-based resins via digital light processing 3D printing is demonstrated and test specimens are successfully 3D printed with a resolution in the millimeter range.

(Meth)acrylate-Free Three-Dimensional Printing of Bio-Derived Photocurable Resins with Terpene- and Itaconic Acid-Derived Poly(ester-thioether)s

Vat photopolymerization, a very efficient and precise object manufacturing technique, still strongly relies on the use of acrylate- and methacrylate-based formulations because of their low cost and high reactivity. However, the environmental impact of using fossil fuel-based, volatile, and toxic (meth)acrylic acid derivatives is driving the scientific community toward the development of alternatives that can match the mechanical performance and three-dimensional (3D) printing processability of traditional photocurable mixtures but are made from environmentally friendly building blocks. Herein, itaconic acid is polymerized with polyols derived from naturally occurring terpenes to produce photocurable poly(ester-thioether)s. The formulation of such polymers using itaconic acid-based reactive diluents allows the preparation of a series of (meth)acrylate-free photocurable resins, which can be 3D printed into solid objects. Extensive analysis has been conducted on the properties of photocured polymers including their thermal, thermomechanical, and mechanical characteristics. The findings suggest that these materials exhibit properties comparable to those of traditional alternatives that are created using harmful and toxic blends. Notably, the photocured polymers are composed of biobased constituents ranging from 75 to 90 wt %, which is among the highest values ever recorded for vat photopolymerization applications.

UV-Curing Additive Manufacturing of Bio-Based Thermosets: Effect of Diluent Concentration on Printing and Material Properties of Itaconic Acid-Based Materials

In the quest toward sustainable thermosets, research has been conducted on various polymer classes like epoxy, benzoxazines, acryl-/methacrylates, etc. One particular group that can also be utilized as sustainable inks for additive manufacturing is itaconic acid-based unsaturated polyester resins. However, due to increased viscosity of the resins, the use of reactive diluents is required to increase their processability. While research has focused on creating different polymeric structures to expand the possible applications, the required amount of diluent has not received equal attention. In this work, a group of itaconic acid-based polyesters was synthesized to create a series of formulations with different reactive diluent contents. The physicochemical properties of the prepared formulations, along with their reactivity toward UV light, were assessed via photo-differential scanning calorimetry (photo-DSC), real-time attenuated total reflectance (RT-ATR), and photorheology measurements. The same formulations were then used to fabricate test specimens via digital light processing (DLP) three-dimensional (3D) printing, which were examined as to their thermomechanical properties by means of dynamic mechanical analysis (DMA) and thermogravimetric analysis (TGA) measurements.