Superstretchable and Processable Silicone Elastomers by Digital Light Processing 3D Printing

Polymers in 3D printing of external maxillofacial prostheses and in their retention systems

Maxillofacial defects, arising from trauma, oncological disease or congenital abnormalities, detrimentally affect daily life. Prosthetic repair offers the aesthetic and functional reconstruction with the help of materials mimicking natural tissues. 3D polymer printing enables the design of patient-specific prostheses with high structural complexity, as well as rapid and low-cost fabrication on-demand. However, 3D printing for prosthetics is still in the early stage of development and faces various challenges for widespread use. This is because the most suitable polymers for maxillofacial restoration are soft materials that do not have the required printability, mechanical strength of the printed parts, as well as functionality. This review focuses on the challenges and opportunities of 3D printing techniques for production of polymer maxillofacial prostheses using computer-aided design and modeling software. Review discusses the widely used polymers, as well as their blends and composites, which meet the most important assessment criteria, such as the physicochemical, biological, aesthetic properties and processability in 3D printing. In addition, strategies for improving the polymer properties, such as their printability, mechanical strength, and their ability to print multimaterial and architectural structures are highlighted. The current state of the prosthetic retention system is presented with a focus on actively used polymer adhesives and the recently implemented prosthesis-supporting osseointegrated implants, with an emphasis on their creation from 3D-printed polymers. The successful prosthetics is discussed in terms of the specificity of polymer materials at the restoration site. The approaches and technological prospects are also explored through the examples of the nasal, auricle and ocular prostheses, ranging from prototypes to end-use products.

Synthesis and Properties of Photocurable Polymers Derived from the Polyesters of Glycerol and Aliphatic Dicarboxylic Acids

The rapid development of 3D printing technology and the emerging applications of shape memory elastomer have greatly stimulated the research of photocurable polymers. In this work, glycerol (Gly) was polycondensed with sebacic, dodecanedioic, or tetradecanedioic acids to provide precursor polyesters with hydroxyl or carboxyl terminal groups, which were further chemically functionalized by acryloyl chloride to introduce sufficient, photocurable, and unsaturated double bonds. The chemical structures of the acrylated polyesters were characterized by FT IR and NMR spectroscopies. The photoinitiated crosslinking behavior of the acrylated polyesters under ultraviolet irradiation without the addition of any photoinitiator was investigated. The results showed that the precursor polyesters that had a greater number of terminated hydroxyls and a less branched structure obtained a relatively high acetylation degree. A longer chain of aliphatic dicarboxylic acids (ADCAs) and higher ADCA proportion lead to a relatively lower photopolymerization rate of acrylated polyesters. However, the photocured elastomers with a higher ADCA proportion or longer-chain ADCAs resulted in better mechanical properties and a lower degradation rate. The glass transition temperature (Tg) of the elastomer increased with the alkyl chain length of the ADCAs, and a higher Gly proportion resulted in a lower Tg of the elastomer due to its higher crosslinking density. Thermal gravimetric analysis (TGA) showed that the chain length of the ADCAs and the molar ratio of Gly to ADCAs had less of an effect on the thermal stability of the elastomer. As the physicochemical properties can be adjusted by choosing the alkyl chain length of the ADCAs, as well as changing the ratio of Gly:ADCA, the photocurable polyesters are expected to be applied in multiple fields.

Three-Dimensional Printing of Ultrasoft Silicone with a Functional Stiffness Gradient

A methodology for three-dimensionally printing ultrasoft silicone with a functional stiffness gradient is presented. Ultraviolet-cure silicone was deposited via two independently controlled extruders into a thixotropic, gel-like, silicone oil-based support matrix. Each extruder contained a different liquid silicone formulation. The extrusion rates were independently varied during printing such that the combined selectively deposited material contained different ratios of the two silicones, resulting in localized control of material stiffness. Tests to validate the process are reported, including tensile testing of homogeneous cubic specimens to quantify the range of material stiffness that could be printed, indentation testing of cuboid specimens to characterize printed stiffness gradients, and vibratory testing of synthetic multilayer vocal fold (VF) models to demonstrate that the method may be applied to the fabrication of biomechanical models for voice production research. The cubic specimens exhibited linear stress-strain data with tensile elasticity modulus values between 1.11 and 27.1 kPa, more than a factor of 20 in stiffness variation. The cuboid specimens exhibited material variations that were visually recognizable and quantifiable via indentation testing. The VF models withstood rigorous phonatory flow-induced vibration and exhibited vibratory characteristics comparable to those of previous models. Overall, while process refinements are needed, the results of these tests demonstrate the ability to print ultrasoft silicone with stiffness gradients.

3D Printing of Self-Healing Materials

This review article presents a comprehensive overview of the latest advances in the field of 3D printable structures with self-healing properties. Three-dimensional printing (3DP) is a versatile technology that enables the rapid manufacturing of complex geometric structures with precision and functionality not previously attainable. However, the application of 3DP technology is still limited by the availability of materials with customizable properties specifically designed for additive manufacturing. The addition of self-healing properties within 3D printed objects is of high interest as it can improve the performance and lifespan of structural components, and even enable the mimicking of living tissues for biomedical applications, such as organs printing. The review will discuss and analyze the most relevant results reported in recent years in the development of self-healing polymeric materials that can be processed via 3D printing. After introducing the chemical and physical self-healing mechanism that can be exploited, the literature review here reported will focus in particular on printability and repairing performances. At last, actual perspective and possible development field will be critically discussed.

Simple Non-Equilibrium Atmospheric Plasma Post-Treatment Strategy for Surface Coating of Digital Light Processed 3D-Printed Vanillin-Based Schiff-Base Thermosets

A simple non-equilibrium atmospheric plasma post-treatment strategy was developed for the surface coating of three-dimensional (3D) structures produced by digital light processing 3D printing. The influence of non-equilibrium atmospheric plasma on the chemical and physical properties of vanillin-derived Schiff-base thermosets and the dip-coating process was investigated and compared to the influence of traditional post-treatment with UV-light. As a comparison, thermosets without post-treatment were also subjected to the coating procedure. The results document that UV post-treatment can induce the completion of the curing of the printed thermosets if complete curing is not reached during printing. Conversely, the plasma post-treatment does not contribute to the curing of the thermoset but causes some opening of the imine bonds and the regeneration of aldehyde functions. As a consequence, no great differences are observed between the not post-treated and plasma post-treated samples in terms of mechanical, thermal, and solvent-resistant properties. In contrast to the UV post-treatment, the plasma post-treatment of the thermosets induces a noticeable increase of the thermoset hydrophilicity ascribed to the reformation of amines on the thermoset surface. The successful coating process and the greatest uniformity of the lignosulfonate coating on the surface of plasma post-treated samples are considered to be due to the presence of these amines and aldehydes. The investigation of the UV shielding properties and antioxidant activities documents the increase of both properties with the increasing amount and uniformity of the formed coating. Interestingly, evident antioxidant properties are also shown by the noncoated thermosets, which are deduced to their chemical structures.

Selective Laser Sintering of Polydimethylsiloxane Composites

Conductive silicone elastomer carbon nanotubes (CNTs) composites possess potential applications in a variety of fields, including electronic skin, wearable electronics, and human motion detection. Based on a novel self-made covalent adaptable network (CANs) of polydimethylsiloxane (PDMS) containg dynamic steric-hindrance pyrazole urea bond (PDMS-CANs), CNTs wrapped PDMS-CANs (CNTs@PDMS-CANs) powders were prepared by a liquid phase adsorption and deposition, and were successfully used for selective laser sintering (SLS) three-dimensional printing. SLS-printed PDMS-CANs/CNTs nanocomposites possess high electrical conductivity and low percolation threshold as SLS is one kind of quasi-static processing, which leads to the formation of conductive segregated CNTs network by using the PDMS powders with special CNTs wrapped structure. The introduction of dynamic pyrazole urea bond endows the materials self-healing capability under electrothermal and photothermal stimulus. In addition, due to the resistance difference of the damaged and intact areas, crack diagnosing can be realized by infrared thermograph under electricity. In an application demonstration in strain sensor, the composite exhibits a regular cyclic electrical resistance change at cyclic compression and bending, indicating a relative high reliability.

3D Printing of High Viscosity UV-Curable Resin for Highly Stretchable and Resilient Elastomer

Elastomers prepared via vat photopolymerizationus ually exhibit unsatisfied mechanical properties owing to their insufficient growth of molecular weight upon UV exposure. Increasing the weight ratio of oligomer in the resin system is an effective approach to enhance the mechanical properties, yet the viscosity of the UV-curable resin increases dramatically; this hinders its printing. In this study, a linear scan-based vat photopolymerization (LSVP) system which can print high-viscosity resins is implemented to 3D print the oligomer-dominated UV-curable resin via a dual-curing mechanism. A polyurethane methacrylate blocking oligomer is first synthesized and then mixed with a commercialized bifunctional oligomer, photoinitiator, and primary amine as a chain extender to prepare high-viscosity UV-curable resin for the LSVP system. The deblocked isocyanate is further crosslinked with a chain extender via thermal treatment to construct a highly entangled polymer chain network. The optimal thermal treatment parameters are investigated, and the resilience of the 3D-printed elastomer is evaluated through continuous tensile loading and unloading tests. Subsequently, complex structured elastomers are printed, exhibiting favorable mechanical durability without defects. The results obtained from this work will provide a reference for preparing elastomeric devices with excellent physical properties and expand the application scope of vat photopolymerization to new fields.

Additive Manufacturing by Heating at a Patterned Photothermal Interface

Direct additive manufacturing (AM) of commercial silicones is an unmet need with high demand. We report a new technology, heating at a patterned photothermal interface (HAPPI), which achieves AM of commercial thermoset resins without any chemical modifications. HAPPI integrates desirable aspects of stereolithography with the thermally driven chemical modalities of commercial silicone formulations. In this way, HAPPI combines the geometric advantages of vat photopolymerization with the materials properties of, for example, injection molded silicones. We describe the realization of the new technology, HAPPI printing using a commercial Sylgard 184 polydimethylsiloxane resin, comparative analyses of material properties, and demonstration of HAPPI in targeted applications.

Single-vat single-cure grayscale digital light processing 3D printing of materials with large property difference and high stretchability

Multimaterial additive manufacturing has important applications in various emerging fields. However, it is very challenging due to material and printing technology limitations. Here, we present a resin design strategy that can be used for single-vat single-cure grayscale digital light processing (g-DLP) 3D printing where light intensity can locally control the conversion of monomers to form from a highly stretchable soft organogel to a stiff thermoset within in a single layer of printing. The high modulus contrast and high stretchability can be realized simultaneously in a monolithic structure at a high printing speed (z-direction height 1 mm/min). We further demonstrate that the capability can enable previously unachievable or hard-to-achieve 3D printed structures for biomimetic designs, inflatable soft robots and actuators, and soft stretchable electronics. This resin design strategy thus provides a material solution in multimaterial additive manufacture for a variety of emerging applications.

Mechanical Evaluation of Hydrogel-Elastomer Interfaces Generated through Thiol-Ene Coupling

The formation of hybrid hydrogel-elastomer scaffolds is an attractive strategy for the formation of tissue engineering constructs and microfabricated platforms for advanced in vitro models. The emergence of thiol-ene coupling, in particular radical-based, for the engineering of cell-instructive hydrogels and the design of elastomers raises the possibility of mechanically integrating these structures without relying on the introduction of additional chemical moieties. However, the bonding of hydrogels (thiol-ene radical or more classic acrylate/methacrylate radical-based) to thiol-ene elastomers and alkene-functional elastomers has not been characterized in detail. In this study, we quantify the tensile mechanical properties of hybrid hydrogel samples formed of two elastomers bonded to a hydrogel material. We examine the impact of radical thiol-ene coupling on the crosslinking of both elastomers (silicone or polyesters) and hydrogels (based on thiol-ene crosslinking or diacrylate chemistry) and on the mechanics and failure behavior of the resulting hybrids. This study demonstrates the strong bonding of thiol-ene hydrogels to alkene-presenting elastomers with a range of chemistries, including silicones and polyesters. Overall, thiol-ene coupling appears as an attractive tool for the generation of strong, mechanically integrated, hybrid structures for a broad range of applications.

3D Printed Silicones with Shape Morphing and Low-Temperature Ultraelasticity

3D printed silicones have demonstrated great potential in diverse areas by combining the advantageous physiochemical properties of silicones with the unparalleled design freedom of additive manufacturing. However, their low-temperature performance, which is of particular importance for polar and space applications, has not been addressed. Herein, a 3D printed silicone foam with unprecedented low-temperature elasticity is presented, which is featured with extraordinary fatigue resistance, excellent shape recovery, and energy-absorbing capability down to a low temperature of -60 °C after extreme compression (an intensive load of over 66000 times its own weight). The foam is achieved by direct writing of a phenyl silicone-based pseudoplastic ink embedded with sodium chloride as sacrificial template. During the water immersion process to create pores in the printed filaments, a unique osmotic pressure-driven shape morphing strategy is also reported, which offers an attractive alternative to traditional 4D printed hydrogels in virtue of the favorable mechanical robustness of the silicone material. The underlying mechanisms for shape morphing and low-temperature elasticity are discussed in detail.

A structural approach to 3D-printing arterial phantoms with physiologically comparable mechanical characteristics: Preliminary observations

Pulse wave behavior is important in cardiovascular pathophysiology and arterial phantoms are valuable for studying arterial function. The ability of phantoms to replicate complex arterial elasticity and anatomy is limited by available materials and techniques. The feasibility of improving phantom performance using functional structure designs producible with practical 3D printing technologies was investigated. A novel corrugated wall approach to separate phantom function from material properties was investigated with a series of designs printed from polyester-polyurethane using a low-cost open-source fused filament fabrication 3D printer. Nonpulsatile pressure-diameter data was collected, and a mock circulatory system was used to observe phantom pulse wave behavior and obtain pulse wave velocities. The measured range of nonpulsatile Peterson elastic strain modulus was 5.6–19 to 12.4–33.0 kPa over pressures of 5–35 mmHg for the most to least compliant designs respectively. Pulse wave velocities of 1.5–5 m s⁻¹ over mean pressures of 7–55 mmHg were observed, comparing favorably to reported in vivo pulmonary artery measurements of 1–4 m s⁻¹ across mammals. Phantoms stiffened with increasing pressure in a manner consistent with arteries, and phantom wall elasticity appeared to vary between designs. Using a functional structure approach, practical low-cost 3D-printed production of simple arterial phantoms with mechanical properties that closely match the pulmonary artery is possible. Further functional structure design development to expand the pressure range and physiologic utility of dir"ectly 3D-printed phantoms appears warranted.

The Use of the Thiol-Ene Addition Click Reaction in the Chemistry of Organosilicon Compounds: An Alternative or a Supplement to the Classical Hydrosilylation?

This review presents the main achievements in the use of the thiol-ene reaction in the chemistry of silicones. Works are considered, starting from monomers and ending with materials.The main advantages and disadvantages of this reaction are demonstrated using various examples. A critical analysis of the use of this reaction is made in comparison with the hydrosilylation reaction.

Synthesis and Optimization of a Free-Radical/Cationic Hybrid Photosensitive UV Curable Resin Using Polyurethane Acrylate and Graphene Oxide

Cost-effective, practical, and efficiently performing photosensitive resin composite materials are essential, as the current materials are expensive, lack better alternatives, and do not meet 3D printing standards. In this study, based on orthogonal experiments for photosensitive resin curing, we prepared a free-radical/cationic hybrid photosensitive UV cured resin (UVR) using acrylic ester and epoxy resin as the prepolymers, tripropylenediol diacrylate (TPGDA) as the active diluent, and triaryl sulfonium salt (I-160) and 2,2-dimethyl-α-hydroxy acetophenone (1173) as the photoinitiators, in the optimized formula of acrylic-ester:epoxy-resin:TPGDA:I-160:1173 = 37.5:37.5:20:2.5:2.5. Further, we investigated the effects of polyurethane acrylates (PUA) and Graphene oxide (GO) on the surface morphology, chemical structure, hydrophobicity, mechanical strength, and gelation rate of the hybrid resin. We observed that 20% PUA improved tensile strength to the maximum of 36.89 MPa from 16.42 MPa of the unmodified hybrid resin, whereas 1% GO reduced volume shrinkage to the minimum of 2.89% from 3.73% of the unmodified hybrid resin. These photosensitive resins with higher tensile strength and lower volume shrinkage can be used to synthesize high performance functional materials in the future.

High-Resolution 3D Printing for Electronics

The ability to form arbitrary 3D structures provides the next level of complexity and a greater degree of freedom in the design of electronic devices. Since recent progress in electronics has expanded their applicability in various fields in which structural conformability and dynamic configuration are required, high-resolution 3D printing technologies can offer significant potential for freeform electronics. Here, the recent progress in novel 3D printing methods for freeform electronics is reviewed, with providing a comprehensive study on 3D-printable functional materials and processes for various device components. The latest advances in 3D-printed electronics are also reviewed to explain representative device components, including interconnects, batteries, antennas, and sensors. Furthermore, the key challenges and prospects for next-generation printed electronics are considered, and the future directions are explored based on research that has emerged recently.

An antibacterial ε-poly-L-lysine-derived bioink for 3D bioprinting applications

Limited bioinks have hindered applying 3D bioprinting to tissue engineering, and bacterial infection is a serious threat to these applications. Aiming to solve this problem, a novel ε-poly-L-lysine (EPL) derived...

Conductive Polymer Nanocomposites for Stretchable Electronics: Material Selection, Design, and Applications

Stretchable electronics that can elongate elastically as well as flex are crucial to a wide range of emerging technologies, such as wearable medical devices, electronic skin, and soft robotics. Critical to stretchable electronics is their ability to withstand large mechanical strain without failure while retaining their electrical conduction properties, a feat significantly beyond traditional metals and silicon-based semiconductors. Herein, we present a review of the recent advances in stretchable conductive polymer nanocomposites with exceptional stretchability and electrical properties, which have the potential to transform a wide range of applications, including wearable sensors for biophysical signals, stretchable conductors and electrodes, and deformable energy-harvesting and -storage devices. Critical to achieving these stretching properties are the judicious selection and hybridization of nanomaterials, novel microstructure designs, and facile fabrication processes, which are the focus of this Review. To highlight the potentials of conductive nanocomposites, a summary of some recent important applications is presented, including COVID-19 remote monitoring, connected health, electronic skin for augmented intelligence, and soft robotics. Finally, perspectives on future challenges and new research opportunities are also presented and discussed.

Digital Light Processing 4D Printing of Transparent, Strong, Highly Conductive Hydrogels

Hydrogels have excellent biocompatibility, transparency, stretchability, and ionic conductivity, but their fabrication through photopolymerization-based 3D printing is limited due to the low solubility of hydrophobic photoinitiators and lack of efficient hydrophilic photoinitiators. Herein, a type of microemulsion is synthesized and the common hydrophobic photoinitiator can be adopted and finally, a series of transparent hydrogels with high strength (up to 22.9 MPa), elasticity (up to 583%), and ionic conductivity (up to 9.64 S m^-1) are fabricated through digital light processing 3D printing technology. Objects with complex structures and a high printing resolution are printed. Hydrogels with both high strength and high ionic conductivity are obtained through chemical crosslinking and ion coordination effect. Dual-material 3D printing is applied to package the hydrogel with elastomers. Due to the high sensitivity and reliability under both stretching and compressive deformation, the hydrogel sensors are applied to monitor various human motions. In addition, the hydrogel exhibits solvent-induced dehydration and excellent water-activated shape memory properties, which are greatly beneficial for its storage and applications in the biomedical field.

3D Printing of High Viscosity Reinforced Silicone Elastomers

Recent advances in additive manufacturing, specifically direct ink writing (DIW) and ink-jetting, have enabled the production of elastomeric silicone parts with deterministic control over the structure, shape, and mechanical properties. These new technologies offer rapid prototyping advantages and find applications in various fields, including biomedical devices, prosthetics, metamaterials, and soft robotics. Stereolithography (SLA) is a complementary approach with the ability to print with finer features and potentially higher throughput. However, all high-performance silicone elastomers are composites of polysiloxane networks reinforced with particulate filler, and consequently, silicone resins tend to have high viscosities (gel- or paste-like), which complicates or completely inhibits the layer-by-layer recoating process central to most SLA technologies. Herein, the design and build of a digital light projection SLA printer suitable for handling high-viscosity resins is demonstrated. Further, a series of UV-curable silicone resins with thiol-ene crosslinking and reinforced by a combination of fumed silica and MQ resins are also described. The resulting silicone elastomers are shown to have tunable mechanical properties, with 100–350% elongation and ultimate tensile strength from 1 to 2.5 MPa. Three-dimensional printed features of 0.4 mm were achieved, and complexity is demonstrated by octet-truss lattices that display negative stiffness.

Fused Filament Fabrication 4D Printing of a Highly Extensible, Self-Healing, Shape Memory Elastomer Based on Thermoplastic Polymer Blends

A polymer blend with high extensibility, exhibiting both shape memory and self-healing, was 4D printed using a low-cost fused filament fabrication (FFF, or fused deposition modeling, FDM) 3D printer. The material is composed of two commercially available commodity polymers, polycaprolactone (PCL), a semi-crystalline thermoplastic, and polystyrene-block-poly(ethylene-co-butylene)-block-polystyrene (SEBS), a thermoplastic elastomer. The shape memory and self-healing properties of the blends were studied systematically through thermo-mechanical and morphological characterization, providing insight into the shape memory mechanism useful for tuning the material properties. In 3D-printed articles, the orientation of the semi-crystalline and micro-phase-separated domains leads to improvement of the shape memory property and extensibility of this material compared to compression-molded samples. By controlling the orientation of the printed fibers, we achieved a high strain at break over 1200%, outperforming previously reported flexible 4D-printed materials. The self-healing agent, PCL, enables the material to heal scratches and cracks and adhere two surfaces after annealing at 80 °C for 30 min. The high performance, multi-functionality, and potential scalability make it a promising candidate for a broad spectrum of applications, including flexible electronics, soft actuators, and deployable devices.

Direct Synthesis of Methyl Chlorosilanes from Pd-Mg-SiO2 Substrates Using Mechanochemistry

The direct reaction of methyl chloride with magnesium and palladium infused silica substrates to synthesize methyl chlorosilanes is reported. First, high energy ball milling on solid Mg-SiO₂ mixtures produces elemental silicon and MgO. When PdCl₂ is infused into the mixture, after additional ball milling and high-temperature reduction under H₂ , dipalladium silicide (Pd₂ Si) is produced. The silicon of the Pd₂ Si readily reacts with MeCl under Müller-Rochow reaction conditions, to produce methyl chlorosilanes at yield ratios analogous to those of the traditional process. The dominant product is Me₂ SiCl₂ (selectivity > 30%), followed by MeSiCl₃ and Me₃ SiCl, with minor amounts of the remaining chlorosilanes. Silicon conversion exceeds 20% for most of the substrates. The elemental palladium, which remains within the Pd-Mg-SiO₂ contact mass is re-converted to Pd₂ Si at the next H₂ /high-temperature treatment and reacts again with MeCl to repeat the methyl chlorosilane production. In principle, the resulting cycle of the mechanochemically induced formation of Pd₂ Si followed by the reaction with MeCl can be repeated until the starting SiO₂ converts completely to methyl chlorosilanes.

Building biobased, degradable, flexible polymer networks from vanillin via thiol–ene “click” photopolymerization

A new biobased allyl ether monomer with acetal groups is synthesized from renewable vanillin for building flexible transparent thiol–ene networks with good degradability under mild acidic conditions.

Zirconia/phenylsiloxane nano-composite for LED encapsulation with high and stable light extraction efficiency

To obtain a rapid processible LED encapsulant that leads to high and stable light extraction efficiency (LEE), UV curable ZrO₂/phenyl-siloxane nano-composite (ZSC) double-layer encapsulants were prepared and optimized. The highly crystalline ZrO₂ nanoparticles with a diameter of ∼14 nm were synthesized through a modified hydrothermal method at mild conditions, and a UV curable methacryl-diphenyl-polysiloxane (MDPS) with a refractive index (RI) of 1.54 (at 633 nm) was synthesized from self-condensation of diphenylsilanediol and an end-capping reaction. High refractive indexes (RIs) from 1.54–1.61 have been obtained for ZSC composites by adding 0–20 wt% ZrO₂. Before and after sulfur vapor erosion, the double-layer encapsulated sample (M-10/M) showed 11.2% and 64.8% higher LEE respectively than that of Dow Corning OE-7662. Meanwhile, the variation of LED light color temperature (T_c) was less than 1%. The effect of the ZrO₂ nanoparticle content on LEE of double-layer and single-layer encapsulation were compared and discussed based on Fresnel loss and Rayleigh scattering theories. The double-layered UV curing processing took only 1/6 of the time needed for common thermal curing.

The double-layer encapsulation by a highly crystalline ZrO₂/polydiphenylsiloxane composite affords 11.2% and 64.8% higher LEE respectively than that of OE-7662 before and after sulfur vapor erosion.

3D Printing of a Polydimethylsiloxane/Polytetrafluoroethylene Composite Elastomer and its Application in a Triboelectric Nanogenerator

Silicone rubber elastomers are broadly used in various fields, where the three-dimensional (3D) printing of silicone rubber elastomers is important for the free construction of complex structures. Herein, a series of polydimethylsiloxane/polytetrafluoroethylene composite inks for direct-ink-writing 3D printing are developed. The inks are prepared by directly mixing a silicone rubber liquid precursor with polytetrafluoroethylene micropowder. The polytetrafluoroethylene micropowder serves as a thixotropic agent to regulate the rheological properties of the polydimethylsiloxane precursor to fulfill the requirement of 3D printing and endow the composite material with high electron affinity. The printed polydimethylsiloxane/polytetrafluoroethylene composite elastomer exhibits excellent elasticity and cyclic stability. A high-performance triboelectric nanogenerator is constructed with the 3D-printed polydimethylsiloxane/polytetrafluoroethylene composite as the triboelectric layer and elastic structure. This work establishes a new method of 3D printing polydimethylsiloxane-based elastomers and thus provides a new technique for constructing complex structures in flexible devices.

Fabrication of a Self-Healing, 3D Printable, and Reprocessable Biobased Elastomer

A novel self-healable, fully reprocessable, and inkjet three-dimensional (3D) printable partially biobased elastomer is reported in this work. A long-chain unsaturated diacrylate monomer was first synthesized from canola oil and then cross-linked with a partially oxidized silicon-based copolymer containing free thiol groups and disulfide bonds. The elastomer is fabricated through inkjet 3D printing utilizing the photoinitiated thiol-ene click chemistry and reprocessed by compression molding exploiting the dynamic nature of disulfide bond. Self-healing is enabled by phosphine-catalyzed disulfide metathesis. The elastomer displayed a tensile strength of ∼52 kPa, a breaking strain of ∼24, and ∼86% healing efficiency at 80 °C temperature after 8 h. Moreover, the elastomer showed excellent thermal stability, and the highest thermal degradation temperature was recorded to be ∼524 °C. After reprocessing through compression molding, the elastomer fully recovered its mechanical and thermal properties. These properties of the elastomer yield an ecofriendly alternative of fossil fuel-based elastomers that can find broad applications in soft robotics, flexible wearable devices, strain sensors, health care, and next-generation energy-harvesting and -storage devices.

3D Printed Silicone Meniscus Implants: Influence of the 3D Printing Process on Properties of Silicone Implants

Osteoarthritis of the knee with meniscal pathologies is a severe meniscal pathology suffered by the aging population worldwide. However, conventional meniscal substitutes are not 3D-printable and lack the customizability of 3D printed implants and are not mechanically robust enough for human implantation. Similarly, 3D printed hydrogel scaffolds suffer from drawbacks of being mechanically weak and as a result patients are unable to execute immediate post-surgical weight-bearing ambulation and rehabilitation. To solve this problem, we have developed a 3D silicone meniscus implant which is (1) cytocompatible, (2) resistant to cyclic loading and mechanically similar to native meniscus, and (3) directly 3D printable. The main focus of this study is to determine whether the purity, composition, structure, dimensions and mechanical properties of silicone implants are affected by the use of a custom-made in-house 3D-printer. We have used the phosphate buffer saline (PBS) absorption test, Fourier transform infrared (FTIR) spectroscopy, surface profilometry, thermo-gravimetric analysis (TGA), X-ray photoelectron spectroscopy (XPS), differential scanning calorimetry (DSC), and scanning electron microscopy (SEM) to effectively assess and compare material properties between molded and 3D printed silicone samples.

A metal-free radical technique for cross-linking of polymethylhydrosiloxane or polymethylvinylsiloxane using AIBN

A new method was developed for the metal-free cross-linking of silicone rubbers. This process uses azobisisobutyronitrile (AIBN) to selectively react with Si-H and vinyl groups as a free-radical initiator for the thermal curing of polymethylhydrosiloxane (PMHS) and polymethylvinylsiloxane (PMVS). The AIBN-initiated curing reaction between the Si-H groups of PMHS generated Si-O-Si and Si-Si cross-links. In contrast, PMVS was cured via the formation of C-C bonds through "methyl-vinyl" and "vinyl-vinyl" mechanisms. Curing reactions were performed at 80-120 °C in air and confirmed by 13C and 29Si solid state NMR analyses and swelling trials.

3D Printing of Viscoelastic Suspensions via Digital Light Synthesis for Tough Nanoparticle-Elastomer Composites

The rheological parameters required to print viscoelastic nanoparticle suspensions toward tough elastomers via Digital Light Synthesis (DLS) (an inverted projection stereolithography system) are reported. With a model material of functionalized silica nanoparticles suspended in a poly(dimethylsiloxane) matrix, the rheological-parameters-guided DLS can print structures seven times tougher than those formed from the neat polymers. The large yield stress and high viscosity associated with these high concentration nanoparticle suspensions, however, may prevent pressure-driven flow, a mechanism essential to stereolithography-based printing. Thus, to better predict and evaluate the printability of high concentration nanoparticle suspensions, the boundary of rheological properties compatible with DLS is defined using a non-dimensional Peclet number (Pe). Based on the proposed analysis of rheological parameters, the border of printability at standard temperature and pressure (STP) is established by resin with a silica nanoparticle mass fraction (ϕ_silica ) of 0.15. Above this concentration, nanoparticle suspensions have Pe > 1 and are not printable. Beyond STP, the printability can be further extended to ϕ_silica = 0.20 via a heating module with lower shear rate to reduce the Pe < 1. The printed rubber possesses even higher toughness (Γ ≈ 155 kJ m^-3 ), which is 40% higher over that of ϕ_silica = 0.15.

Advancements in Soft-Tissue Prosthetics Part A: The Art of Imitating Life

Physical disfigurement due to congenital defects, trauma, or cancer causes considerable distress and physical impairment for millions of people worldwide; impacting their economic, psychological and social wellbeing. Since 3000 B.C., prosthetic devices have been used to address these issues by restoring both aesthetics and utility to those with disfigurement. Internationally, academic and industry researchers are constantly developing new materials and manufacturing techniques to provide higher quality and lower cost prostheses to those people who need them. New advanced technologies including 3D imaging, modeling, and printing are revolutionizing the way prostheses are now made. These new approaches are disrupting the traditional and manual art form of prosthetic production which are laborious and costly and are being replaced by more precise and quantitative processes which enable the rapid, low cost production of patient-specific prostheses. In this two part review, we provide a comprehensive report of past, present and emerging soft-tissue prosthetic materials and manufacturing techniques. In this review, part A, we examine, historically, the ideal properts of a polymeric material when applied in soft-tissue prosthetics. We also detail new research approaches to target specific tissues which commonly require aesthetic restoration (e.g. ear, nose and eyes) and discuss both traditional and advanced fabrication methods, from hand-crafted impression based approaches to advanced manufactured prosthetics. We discuss the chemistry and related details of most significant synthetic polymers used in soft-tissue prosthetics in Part B. As advanced manufacturing transitions from research into practice, the five millennia history of prosthetics enters a new age of economic, personalized, advanced soft tissue prosthetics and with this comes significantly improved quality of life for the people affected by tissue loss.

3D Printing Mechanically Robust and Transparent Polyurethane Elastomers for Stretchable Electronic Sensors

Advanced stretchable electronic sensors with a complex structure place higher requirements on the mechanical properties and manufacturing process of the stretchable substrate materials. Herein, three kinds of polyurethane acrylate oligomers were synthesized successfully and mixed with a commercial acrylate monomer (isobornyl acrylate) to prepare photocurable resins with a low viscosity for a digital light processing three-dimensional (3D) printer without custom equipment. Results showed that the resin containing poly(tetrahydrofuran) units (PPTMGA-40) exhibited optimal mechanical properties and shape recoverability. The tensile strength and elongation at break of PPTMGA-40 were 15.7 MPa and 414.3%, respectively. The unprecedented fatigue resistance of PPTMGA-40 allowed it to withstand 100 compression cycles at 80% strain without fracture. The transmittance of PPTMGA-40 reached 89.4% at 550 nm, showing high transparency. An ionic hydrogel was coated on the surface of 3D-printed structures to fabricate stretchable sensors, and their conductivity, transparency, and mechanical performance were characterized. A robust piezoresistive strain sensor with a high strength (∼6 MPa) and a wearable finger guard sensor were fabricated, demonstrating that this hydrogel-elastomer system can meet the requirements of applications for advanced stretchable electronic sensors and expand the usage scope.

Self-Healing Polyurethane Elastomers Based on a Disulfide Bond by Digital Light Processing 3D Printing

A type of polyurethane elastomer with excellent self-healing ability has been fabricated through digital light processing 3D printing. First, a type of polyurethane acrylate containing disulfide bonds is synthesized and then compounded with reactive diluent and photoinitiators to get a photopolymer resin. Due to the good fluidity and high curing rate, the photopolymer resin can be applied in DLP 3D printing, and various 3D objects with complicated structures, high printing accuracy, and remarkable self-healing ability have been printed. The tensile strength and elongation at break of the polyurethane elastomer are 3.39 ± 0.09 MPa and 400.38 ± 14.26%, respectively, and the healing efficiency can get to 95% after healing at 80 °C for 12 h and can be healed for multiple times. With the ease of fabrication and excellent performance, the polyurethane elastomers from DLP 3D printing have great potential applications in flexible electronics, soft robotics, and sensors.