100th Anniversary of Macromolecular Science Viewpoint: Macromolecular Materials for Additive Manufacturing

Silicon-photonics-enabled chip-based 3D printer

Imagine if it were possible to create 3D objects in the palm of your hand within seconds using only a single photonic chip. Although 3D printing has revolutionized the way we create in nearly every aspect of modern society, current 3D printers rely on large and complex mechanical systems to enable layer-by-layer addition of material. This limits print speed, resolution, portability, form factor, and material complexity. Although there have been recent efforts in developing novel photocuring-based 3D printers that utilize light to transform matter from liquid resins to solid objects using advanced methods, they remain reliant on bulky and complex mechanical systems. To address these limitations, we combine the fields of silicon photonics and photochemistry to propose the first chip-based 3D printer. The proposed system consists of only a single millimeter-scale photonic chip without any moving parts that emits reconfigurable visible-light holograms up into a simple stationary resin well to enable non-mechanical 3D printing. Furthermore, we experimentally demonstrate a stereolithography-inspired proof-of-concept version of the chip-based 3D printer using a visible-light beam-steering integrated optical phased array and visible-light-curable resin, showing 3D printing using a chip-based system for the first time. This work demonstrates the first steps towards a highly-compact, portable, and low-cost solution for the next generation of 3D printers.

Engineered Living Material Bioreactors with Tunable Mechanical Properties using Vat Photopolymerization

3D-printed engineered living materials (ELM) are promising bioproduction platforms for agriculture, biotechnology, sustainable energy, and green technology applications. However, the design of these platforms faces several challenges, such as the processability of these materials into complex form factors and control over their mechanical properties. Herein, ELM are presented as 3D-printed bioreactors with arbitrary shape geometries and tunable mechanical properties (moduli and toughness). Poly(ethylene glycol) diacrylate (PEGDA) is used as the precursor to create polymer networks that encapsulate the microorganisms during the vat photopolymerization process. A major limitation of PEGDA networks is their propensity to swell and fracture when submerged in water. The authors overcame this issue by adding glycerol to the resin formulation to 3D print mechanically tough ELM hydrogels. While polymer concentration affects the modulus and reduces bioproduction, ELM bioreactors still maintain their metabolic activity regardless of polymer concentration. These ELM bioreactors have the potential to be used in different applications for sustainable architecture, food production, and biomedical devices that require different mechanical properties from soft to stiff.

Novel D-π-A hemicyanine dye as photoinitiators for in situ hydrogel formation and DLP printing

The field of biofabrication imposes stringent requirements on the polymerization activity and biosafety of photopolymeric hydrogel systems. In this investigation, we designed and synthesized four hemicyanine dyes with a D-π-A structure specifically tailored for biofabrication purposes. These novel dyes, incorporating carbazole (CZ), triphenylamine (TPA), anthracene (AN), and benzodithiophene (BDT) as electron donors, along with heterocyclic salt (IN) as electron acceptors, were prepared using a straightforward synthesis method. The absorption maxima of ANIN, CZIN, and TPAIN exceeded 500 nm, rendering them suitable co-initiators for the free radical photopolymerization of acrylates under green-red light exposure facilitated by light-emitting diodes (LEDs) and the co-initiator iodonium salt (ION). Notably, CZIN and TPAIN, due to their robust dye absorption and efficient electron transfer to ION, functioned as high-performance photosensitizers. Meanwhile, BDTIN, with its strong and broad absorption range (400-600 nm), enhanced the accuracy of visible light photopolymerization. These dyes exhibit characteristics such as facile synthesis, heightened photo stability, and non-toxicity and also demonstrate the ability to discern the alkalinity of a solution to some extent. Furthermore, we explored the application of these hemicyanine dyes in 3D printing, showing potential to enhance printing resolution in DLP 3D printing (digital light process 3D printing).

4D Printed Protein-AuNR Nanocomposites with Photothermal Shape Recovery

4D printing is the 3D printing of objects that change chemically or physically in response to an external stimulus over time. Photothermally responsive shape memory materials are attractive for their ability to undergo remote activation. While photothermal methods using gold nanorods (AuNRs) have been used for shape recovery, 3D patterning of these materials into objects with complex geometries using degradable materials has not been addressed. Here, we report on the fabrication of 3D printed shape memory bioplastics with photo-activated shape recovery. Protein-based nanocomposites based on bovine serum albumin (BSA), poly (ethylene glycol) diacrylate and gold nanorods were developed for vat photopolymerization. These 3D printed bioplastics were mechanically deformed under high loads, and the proteins served as mechanoactive elements that unfolded in an energy-dissipating mechanism that prevented fracture of the thermoset. The bioplastic object maintained its metastable shape-programmed state under ambient conditions. Subsequently, up to 99% shape recovery was achieved within 1 min of irradiation with near-infrared light. Mechanical characterization and small angle X-ray scattering (SAXS) analysis suggest that the proteins mechanically unfold during the shape programming step and may refold during shape recovery. These composites are promising materials for the fabrication of biodegradable shape-morphing devices for robotics and medicine.

Multijet Gold Nanoparticle Inks for Additive Manufacturing of Printed and Wearable Electronics

Conductive and biofriendly gold nanomaterial inks are highly desirable for printed electronics, biosensors, wearable electronics, and electrochemical sensor applications. Here, we demonstrate the scalable synthesis of stable gold nanoparticle inks with low-temperature sintering using simple chemical processing steps. Multiprinter compatible aqueous gold nanomaterial inks were formulated, achieving resistivity as low as ∼10-6 Ω m for 400 nm thick films sintered at 250 °C. Printed lines with a resolution of <20 μm and minimal overspray were obtained using an aerosol jet printer. The resistivity of the printed patterns reached ∼9.59 ± 1.2 × 10-8 Ω m after sintering at 400 °C for 45 min. Our aqueous-formulated gold nanomaterial inks are also compatible with inkjet printing, extending the design space and manufacturability of printed and flexible electronics where metal work functions and chemically inert films are important for device applications.

Mechanical Properties' Strengthening of Photosensitive 3D Resin in Lithography Technology Using Acrylated Natural Rubber

Acrylated natural rubber (ANR) with various acrylate contents (0.0-3.5 mol%) was prepared from natural rubber as a raw material and then incorporated with commercial 3D resin to fabricate specimens using digital light processing. As a result, the utilization of ANR with 1.5 mol% acrylate content could provide the maximum improvement in stretchability and impact strength, approximately 155% and 221%, respectively, over using pure 3D resin, without significant deterioration of tensile modulus and mechanical strength. According to evidence from a scanning electron microscope, this might be due to the partial interaction between the dispersed small rubber particles and the resin matrix. Additionally, the glass-transition temperature of the 3D-printed sample shifted to a lower temperature by introducing a higher acrylate content in the ANR. Therefore, this work might offer a practical way to effectively enhance the properties of the fundamental commercial 3D resin and broaden its applications. It also makes it possible to use natural rubber as a bio-based material in light-based 3D printing.

Recyclable photoresins for light-mediated additive manufacturing towards Loop 3D printing

Additive manufacturing (AM) of polymeric materials enables the manufacturing of complex structures for a wide range of applications. Among AM methods vat photopolymerization (VP) is desired owing to improved efficiency, excellent surface finish, and printing resolution at the micron-scale. Nevertheless, the major portion of resins available for VP are based on systems with limited or negligible recyclability. Here, we describe an approach that enables the printing of a resin that is amenable to re-printing with retained properties and appearance. To that end, we take advantage of the potential of polythiourethane chemistry, which not only permits the click reaction between polythiols and polyisocyanates in the presence of organic bases, allowing a fast-printing process but also chemical recycling, reshaping, and reparation of the printed structures, paving the way toward the development of truly sustainable recyclable photoprintable resins. We demonstrate that this closed-loop 3D printing process is feasible both at the macroscale and microscale via DLP or DLW, respectively.

Boron-Methylated Dipyrromethene as a Green Light Activated Type I Photoinitiator for Rapid Radical Polymerizations

Unimolecular (Type I) radical photoinitiators (PIs) have transformed the chemical manufacturing industry by enabling (stereo)lithography for microelectronics and emergent 3D printing technologies. However, the reliance on high energy UV-violet light (≤420 nm) restricts the end-use applications. Herein, boron-methylated dipyrromethene (methylated-BODIPY) is shown to act as a highly efficient Type I radical PI upon irradiation with low energy green light. Using a low intensity (∼4 mW/cm2) light emitting diode centered at 530 nm and a low PI concentration (0.3 mol %), acrylic-based resins were polymerized to maximum conversion in ∼10 s. Under equivalent conditions (wavelength, intensity, and PI concentration), state-of-the-art visible light PIs Ivocerin and Irgacure 784 show no appreciable polymerization. Spectroscopic characterization suggests that homolytic β-scission at the boron-carbon bond results in radical formation, which is further facilitated by accessing long-lived triplet excited states through installment of bromine. Alkylated-BODIPYs represent a new modular visible light PI platform with exciting potential to enable next generation manufacturing and biomedical applications where a spectrally discrete, low energy, and thus benign light source is required.

Digital Light Processing 3D Printing of Soft Semicrystalline Acrylates with Localized Shape Memory and Stiffness Control

Multimaterial three-dimensional (3D) printing of objects with spatially tunable thermomechanical properties and shape-memory behavior provides an attractive approach toward programmable "smart" plastics with applications in soft robotics and electronics. To date, digital light processing 3D printing has emerged as one of the fastest manufacturing methods that maintains high precision and resolution. Despite the common utility of semicrystalline polymers in stimuli-responsive materials, few reports exist whereby such polymers have been produced via digital light processing (DLP) 3D printing. Herein, two commodity long-alkyl chain acrylates (C₁₈, stearyl and C₁₂, lauryl) and mixtures therefrom are systematically examined as neat resin components for DLP 3D printing of semicrystalline polymer networks. Tailoring the stearyl/lauryl acrylate ratio results in a wide breadth of thermomechanical properties, including tensile stiffness spanning three orders of magnitude and temperatures from below room temperature (2 °C) to above body temperature (50 °C). This breadth is attributed primarily to changes in the degree of crystallinity. Favorably, the relationship between resin composition and the degree of crystallinity is quadratic, making the thermomechanical properties reproducible and easily programmable. Furthermore, the shape-memory behavior of 3D-printed objects upon thermal cycling is characterized, showing good fatigue resistance and work output. Finally, multimaterial 3D-printed structures with vertical gradation in composition are demonstrated where concomitant localization of thermomechanical properties enables multistage shape-memory and strain-selective behavior. The present platform represents a promising route toward customizable actuators for biomedical applications.

Additive Manufacturing of Engineered Living Materials with Bio-augmented Mechanical Properties and Resistance to Degradation

Engineered living materials (ELMs) combine living cells with polymeric matrices to yield unique materials with programmable functions. While the cellular platform and the polymer network determine the material properties and applications, there are still gaps in our ability to seamlessly integrate the biotic (cellular) and abiotic (polymer) components into singular material, then assemble them into devices and machines. Herein, we demonstrated the additive-manufacturing of ELMs wherein bioproduction of metabolites from the encapsulated cells enhanced the properties of the surrounding matrix. First, we developed aqueous resins comprising bovine serum albumin (BSA) and poly(ethylene glycol diacrylate) (PEGDA) with engineered microbes for vat photopolymerization to create objects with a wide array of 3D form factors. The BSA-PEGDA matrix afforded hydrogels that were mechanically stiff and tough for use in load-bearing applications. Second, we demonstrated the continuous in situ production of L-DOPA, naringenin, and betaxanthins from the engineered cells encapsulated within the BSA-PEGDA matrix. These microbial metabolites bioaugmented the properties of the BSA-PEGDA matrix by enhancing the stiffness (L-DOPA) or resistance to enzymatic degradation (betaxanthin). Finally, we demonstrated the assembly of the 3D printed ELM components into mechanically functional bolts and gears to showcase the potential to create functional ELMs for synthetic living machines.

Advanced supramolecular design for direct ink writing of soft materials

The exciting advancements in 3D-printing of soft materials are changing the landscape of materials development and fabrication. Among various 3D-printers that are designed for soft materials fabrication, the direct ink writing (DIW) system is particularly attractive for chemists and materials scientists due to the mild fabrication conditions, compatibility with a wide range of organic and inorganic materials, and the ease of multi-materials 3D-printing. Inks for DIW need to possess suitable viscoelastic properties to allow for smooth extrusion and be self-supportive after printing, but molecularly facilitating 3D printability to functional materials remains nontrivial. While supramolecular binding motifs have been increasingly used for 3D-printing, these inks are largely optimized empirically for DIW. Hence, this review aims to establish a clear connection between the molecular understanding of the supramolecularly bound motifs and their viscoelastic properties at bulk. Herein, extrudable (but not self-supportive) and 3D-printable (self-supportive) polymeric materials that utilize noncovalent interactions, including hydrogen bonding, host-guest inclusion, metal-ligand coordination, micro-crystallization, and van der Waals interaction, have been discussed in detail. In particular, the rheological distinctions between extrudable and 3D-printable inks have been discussed from a supramolecular design perspective. Examples shown in this review also highlight the exciting macroscale functions amplified from the molecular design. Challenges associated with the hierarchical control and characterization of supramolecularly designed DIW inks are also outlined. The perspective of utilizing supramolecular binding motifs in soft materials DIW printing has been discussed. This review serves to connect researchers across disciplines to develop innovative solutions that connect top-down 3D-printing and bottom-up supramolecular design to accelerate the development of 3D-print soft materials for a sustainable future.

Chemistry in light-induced 3D printing

In the last few years, 3D printing has evolved from its original niche applications, such as rapid prototyping and hobbyists, towards many applications in industry, research and everyday life. This involved an evolution in terms of equipment, software and, most of all, in materials. Among the different available 3D printing technologies, the light activated ones need particular attention from a chemical point of view, since those are based on photocurable formulations and in situ rapid solidification via photopolymerization. In this article, the chemical aspects beyond the preparation of a formulation for light-induced 3D printing are analyzed and explained, aiming at giving more tools for the development of new photocurable materials that can be used for the fabrication of innovative 3D printable devices.

Graphical abstract

Advanced Formulations Based on Poly(ionic liquid) Materials for Additive Manufacturing

Innovation in materials specially formulated for additive manufacturing is of great interest and can generate new opportunities for designing cost-effective smart materials for next-generation devices and engineering applications. Nevertheless, advanced molecular and nanostructured systems are frequently not possible to integrate into 3D printable materials, thus limiting their technological transferability. In some cases, this challenge can be overcome using polymeric macromolecules of ionic nature, such as polymeric ionic liquids (PILs). Due to their tuneability, wide variety in molecular composition, and macromolecular architecture, they show a remarkable ability to stabilize molecular and nanostructured materials. The technology resulting from 3D-printable PIL-based formulations represents an untapped array of potential applications, including optoelectronic, antimicrobial, catalysis, photoactive, conductive, and redox applications.

Spotting Trends in Organocatalyzed and Other Organomediated (De)polymerizations and Polymer Functionalizations

Organocatalysis has evolved into an effective complement to metal‐ or enzyme‐based catalysis in polymerization, polymer functionalization, and depolymerization. The ease of removal and greater sustainability of organocatalysts relative to transition‐metal‐based ones has spurred development in specialty applications, e.g., medical devices, drug delivery, optoelectronics. Despite this, the use of organocatalysis and other organomediated reactions in polymer chemistry is still rapidly developing, and we envisage their rapidly growing application in nascent areas such as controlled radical polymerization, additive manufacturing, and chemical recycling in the coming years. In this Review, we describe ten trending areas where we anticipate paradigm shifts resulting from novel organocatalysts and other transition‐metal‐free conditions. We highlight opportunities and challenges and detail how new discoveries could lead to previously inaccessible functional materials and a potentially circular plastics economy.

Direct Ink Writing of Recyclable Supramolecular Soft Actuators

Direct ink writing (DIW) of liquid crystal elastomers (LCEs) has rapidly paved its way into the field of soft actuators and other stimuli-responsive devices. However, currently used LCE systems for DIW require postprinting (photo)polymerization, thereby forming a covalent network, making the process time-consuming and the material nonrecyclable. In this work, a DIW approach is developed for printing a supramolecular poly(thio)urethane LCE to overcome these drawbacks of permanent cross-linking. The thermo-reversible nature of the supramolecular cross-links enables the interplay between melt-processable behavior required for extrusion and formation of the network to fix the alignment. After printing, the actuators demonstrated a reversible contraction of 12.7% or bending and curling motions when printed on a passive substrate. The thermoplastic ink enables recyclability, as shown by cutting and printing the actuators five times. However, the actuation performance diminishes. This work highlights the potential of supramolecular LCE inks for DIW soft circular actuators and other devices.

3D Printing of Metal-Organic Framework-Based Ionogels: Wearable Sensors with Colorimetric and Mechanical Responses

Soft ionotronics are emerging materials as wearable sensors for monitoring physiological signals, sensing environmental hazards, and bridging the human-machine interface. However, the next generation of wearable sensors requires multiple sensing capabilities, mechanical toughness, and 3D printability. In this study, a metal-organic framework (MOF) and three-dimensional (3D) printing were integrated for the synthesis of a tough MOF-based ionogel (MIG) for colorimetric and mechanical sensing. The ink for 3D printing contained deep eutectic solvents (DESs), cellulose nanocrystals (CNCs), MOF crystals, and acrylamide. After printing, further photopolymerization resulted in a second covalently cross-linked poly(acrylamide) network and solidification of MIG. As a porphyrinic Zr-based MOF, MOF-525 served as a functional filler to provide sharp color changes when exposed to acidic compounds. Notably, MOF-525 crystals also provided another design space to tune the printability and mechanical strength of MIG. In addition, the printed MIG exhibited high stability in the air because of the low volatility of DESs. Thereafter, wearable auxetic materials comprising MIG with negative Poisson's ratios were prepared by 3D printing for the detection of mechanical deformation. The resulting auxetic sensor exhibited high sensitivity via the change in resistance upon mechanical deformation and a conformal contact with skins to monitor various human body movements. These results demonstrate a facile strategy for the construction of multifunctional sensors and the shaping of MOF-based composite materials.

FDM Printability of PLA Based-Materials: The Key Role of the Rheological Behavior

Fused deposition modeling (FDM) is one of the most commonly used commercial technologies of materials extrusion-based additive manufacturing (AM), used for obtaining 3D-printed parts using thermoplastic polymers. Notwithstanding the great variety of applications for FDM-printed objects, the choice of materials suitable for processing using AM technology is still limited, likely due to the lack of rapid screening procedures allowing for an efficient selection of processable polymer-based formulations. In this work, the rheological behavior of several 3D-printable, commercially available poly(lactic acid)-based filaments was accurately characterized. In particular, each step of a typical FDM process was addressed, from the melt flowability through the printing nozzle, to the interlayer adhesion in the post-deposition stage, evaluating the ability of the considered materials to fulfill the criteria for successful 3D printing using FDM technology. Furthermore, the rheological features of the investigated materials were related to their composition and microstructure. Although an exhaustive and accurate evaluation of the 3D printability of thermoplastics must also consider their thermal behavior, the methodology proposed in this work aimed to offer a useful tool for designing thermoplastic-based formulations that are able to ensure an appropriate rheological performance in obtaining 3D-printed parts with the desired geometry and final properties.

Fast Visible-Light Photopolymerization in the Presence of Multiwalled Carbon Nanotubes: Toward 3D Printing Conducting Nanocomposites

A new photoinitiator system (PIS) based on riboflavin (Rf), triethanolamine, and multiwalled carbon nanobutes (MWCNTs) is presented for visible-light-induced photopolymerization of acrylic monomers. Using this PIS, photopolymerization of acrylamide and other acrylic monomers was quantitative in seconds. The intervention mechanism of CNTs in the PIS was studied deeply, proposing a surface interaction of MWCNTs with Rf which favors the radical generation and the initiation step. As a result, polyacrylamide/MWCNT hydrogel nanocomposites could be obtained with varying amounts of CNTs showing excellent mechanical, thermal, and electrical properties. The presence of the MWCNTs negatively influences the swelling properties of the hydrogel but significantly improves its mechanical properties (Young modulus values) and electric conductivity. The new PIS was tested for 3D printing in a LCD 3D printer. Due to the fast polymerizations, 3D-printed objects based on the conductive polyacrylamide/CNT nanocomposites could be manufactured in minutes.

Modeling the Enhanced Efficacy and Curing Depth of Photo-Thermal Dual Polymerization in Metal (Fe) Polymer Composites for 3D Printing

This article presents, for the first time, the efficacy and curing depth analysis of photo-thermal dual polymerization in metal (Fe) polymer composites for 3D printing of a three-component (A/B/M) system based on the proposed mechanism of our group, in which the co initiators A and B are Irgacure-369 and charge-transfer complexes (CTC), respectively, and the monomer M is filled by Fe. Our formulas show the depth of curing (Zc) is an increasing function of the light intensity, but a decreasing function of the Fe and photoinitiator concentrations. Zc is enhanced by the additive [B], which produces extra thermal radical for polymerization under high temperature. The heat (or temperature) increase in the system has two components: (i) due to the light absorption of Fe filler and (ii) heat released from the exothermic photopolymerization of the monomer. The heat is transported to the additive (or co-initiator) [B] to produce extra radicals and enhance the monomer conversion function (CF). The Fe filler leads to a temperature increase but also limits the light penetration, leading to lower CF and Zc, which could be overcome by the additive initiator [B] in thick polymers. Optimal Fe for maximal CF and Zc are explored theoretically. Measured data are analyzed based on our derived formulas.

Digital Light Processing 3D Printing of Enhanced Polymers via Interlayer Welding

Digital light processing (DLP) 3D printing is advantageous in high printing efficiency and printing resolution for fabricating complex structures across various applications. However, the layer-by-layer curing manner of DLP leads to weak interlayer adhesion and the anisotropic mechanical properties of printed objects. Here, linear polymers are introduced into commercial resins to weld the interlayer by the diffusion and entanglement of linear polymers after DLP printing via heat treatment. This introduction of linear polymers not only shows a strengthening and toughening effect on the printed objects, but also has no negative impact on the DLP printability. The tensile strengths of objects containing 4.7wt% polycaprolactone can reach up to ∼500% of that of neat samples in any printing direction. This simple strategy by adding linear polymers into printing resins provides an effective access to prepare DLP printed objects with improved mechanical properties as well as ensure printing resolution and printing efficiency. This article is protected by copyright. All rights reserved.

"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.

Electroactive 3D printable poly(3,4-ethylenedioxythiophene)-graft-poly(ε-caprolactone) copolymers as scaffolds for muscle cell alignment

Graft copolymers between conducting PEDOT and biodegradable PCL were synthesized and investigated for 3D printing scaffolds for patterning of muscle cells.

Rapid digital light 3D printing enabled by a soft and deformable hydrogel separation interface

The low productivity of typical 3D printing is a major hurdle for its utilization in large-scale manufacturing. Innovative techniques have been developed to break the limitation of printing speed, however, sophisticated facilities or costly consumables are required, which still substantially restricts the economic efficiency. Here we report that a common stereolithographic 3D printing facility can achieve a very high printing speed (400 mm/h) using a green and inexpensive hydrogel as a separation interface against the cured part. In sharp contrast to other techniques, the unique separation mechanism relies on the large recoverable deformation along the thickness direction of the hydrogel interface during the layer-wise printing. The hydrogel needs to be extraordinarily soft and unusually thick to remarkably reduce the adhesion force which is a key factor for achieving rapid 3D printing. This technique shows excellent printing stability even for fabricating large continuous solid structures, which is extremely challenging for other rapid 3D printing techniques. The printing process is highly robust for fabricating diversified materials with various functions. With the advantages mentioned above, the presented technique is believed to make a large impact on large-scale manufacturing.

Chemical and Mechanical Tunability of 3D-Printed Dynamic Covalent Networks Based on Boronate Esters

As the scope of additive manufacturing broadens, interest has developed in 3D-printed objects that are derived from recyclable resins with chemical and mechanical tunability. Dynamic covalent bonds have the potential to not only increase the sustainability of 3D-printed objects, but also serve as reactive sites for postprinting derivatization. In this study, we use boronate esters as a key building block for the development of catalyst-free, 3D-printing resins with the ability to undergo room-temperature exchange at the cross-linking sites. The orthogonality of boronate esters is exploited in fast-curing, oxygen-tolerant thiol-ene resins in which the dynamic character of 3D-printed objects can be modulated by the addition of a static, covalent cross-linker with no room-temperature bond exchange. This allows the mechanical properties of printed parts to be varied between those of a traditional thermoset and a vitrimer. Objects printed with a hybrid dynamic/static resin exhibit a balance of structural stability (residual stress = 18%) and rapid exchange (characteristic relaxation time = 7 s), allowing for interfacial welding and postprinting functionalization. Modulation of the cross-linking density postprinting is enabled by selective hydrolysis of the boronate esters to generate networks with swelling capacities tunable from 1.3 to 3.3.

3D Printable Conducting and Biocompatible PEDOT-graft-PLA Copolymers by Direct Ink Writing

Tailor-made polymers are needed to fully exploit the possibilities of additive manufacturing, constructing complex, and functional devices in areas such as bioelectronics. In this paper, the synthesis of a conducting and biocompatible graft copolymer which can be 3D printed using direct melting extrusion methods is shown. For this purpose, graft copolymers composed by conducting polymer poly(3,4-ethylenedioxythiophene) (PEDOT) and a biocompatible polymer polylactide (PLA) are designed. The PEDOT-g-PLA copolymers are synthesized by chemical oxidative polymerization between 3,4-ethylenedioxythiophene and PLA macromonomers. PEDOT-g-PLA copolymers with different compositions are obtained and fully characterized. The rheological characterization indicates that copolymers containing below 20 wt% of PEDOT show the right complex viscosity values suitable for direct ink writing (DIW). The 3D printing tests using the DIW methodology allows printing different parts with different shapes with high resolution (200 µm). The conductive and biocompatible printed patterns of PEDOT-g-PLA show excellent cell growth and maturation of neonatal cardiac myocytes cocultured with fibroblasts.

3D-Printed Bioplastics with Shape-Memory Behavior Based on Native Bovine Serum Albumin

Bio-based plastics that can supplant petroleum-derived materials are necessary to meet the future demands of sustainability in the life cycle of plastic materials. While there are significant efforts to develop protein-based plastic materials for commercial use, their application is limited by poor processability and limitations in mechanical performance. Here, we present a bovine serum albumin (BSA)-based resin for stereolithographic apparatus (SLA) 3D printing that affords bioplastic objects with shape-memory behavior. We demonstrate that the native conformation of these globular proteins is largely retained in the 3D-printed constructs and that each protein molecule possesses a "stored length" that could be revealed during mechanical deformation (extension or compression) of the 3D bioplastic objects. While the plastically deformed objects could retain this state for an indefinite period of time, heating the object or submerging in water allowed it to return to its original 3D-printed shape.

Mechanoactivation of Color and Autonomous Shape Change in 3D-Printed Ionic Polymer Networks

Stimuli-responsive materials can enhance the field of three-dimensional (3D) printing by generating objects that change shape in response to external cues. While temperature and pH are common inputs for initiating a response in a 3D-printed object, there are few examples of using a mechanical input to afford a response. Herein, we report a suite of mechanochromic ionic liquid gel inks that can be used to fabricate 3D-printed objects that use a single mechanoactivation event to elicit both a mechanochromic response and an autonomous shape change. Direct-ink write 3D printing was used to deposit ionic liquid gel inks to create multimaterial objects that underwent a predetermined mechanoactivated shape change (mechanomorphic) when the sample was pulled and then released. When spiropyran was incorporated into the inks, the onset of spiropyran isomerization into its purple merocyanine form occurred at strains dependent upon the particular ion gel ink formulation. We suggest that the color onset could be used as a simple indicator for when the strain required to achieve a predetermined change in shape has been reached, potentially serving as real-time visual cue for the user. Such morphing 3D-printed structures with integrated instructions have potential application to areas including stowable structures as well as multiresponsive autonomous components and sensors.

Balancing Self-Healing and Shape Stability in Dynamic Covalent Photoresins for Stereolithography 3D Printing

Dynamic covalent bonds impart new properties to 3D printable materials that help to establish 3D printing as an accessible and efficient manufacturing technique. Here, we studied the effect of a thermally reversible Diels-Alder cross-linker on the shape stability of photoprintable resins and their self-healing properties. Resins containing different concentrations of dynamic covalent cross-links in a polyacrylate network showed that the content of dynamic cross-links plays a key role in balancing shape stability with self-healing ability. The shape stability of the printed objects was evaluated by measuring the dimensional changes after thermal treatment. The self-healing efficiency of the 3D printed resins was characterized with a scratch test and tensile testing. A dynamic covalent cross-link concentration of 1.8 mol % was enough to provide 99% self-healing efficiency without disrupting the shape stability of the printed objects. Our work shows the potential of dynamic covalent bonds in broadening the availability of 3D printable materials that are compatible with vat photopolymerization.

The molecular design of photo-curable and high-strength benzoxazine for 3D printing

Low viscosity photo-curable benzoxazines (BZs) are designed and synthesized for use in stereolithography 3D printing. An initial investigation shows that the thermally polymerized polybenzoxazines (PBZs) have remarkably high T_g (264 °C) and flexural modulus (4.91 GPa) values. Subsequently, the formulated photoprintable resins are employed for use in high-resolution projection micro-stereolithography (PμSL) printing. Complex PBZ 3D structures can be achieved from the as-printed objects after they are thermally treated. These findings advance the design of BZ monomers for photopolymerization-based 3D printing and offer a method for the efficient fabrication of high-performance thermosets for various demanding engineering applications.

Amyloid-Like Aggregation in Diseases and Biomaterials: Osmosis of Structural Information

The discovery that the polypeptide chain has a remarkable and intrinsic propensity to form amyloid-like aggregates endowed with an extraordinary stability is one of the most relevant breakthroughs of the last decades in both protein/peptide chemistry and structural biology. This observation has fundamental implications, as the formation of these assemblies is systematically associated with the insurgence of severe neurodegenerative diseases. Although the ability of proteins to form aggregates rich in cross-β structure has been highlighted by recent studies of structural biology, the determination of the underlying atomic models has required immense efforts and inventiveness. Interestingly, the progressive molecular and structural characterization of these assemblies has opened new perspectives in apparently unrelated fields. Indeed, the self-assembling through the cross-β structure has been exploited to generate innovative biomaterials endowed with promising mechanical and spectroscopic properties. Therefore, this structural motif has become the fil rouge connecting these diversified research areas. In the present review, we report a chronological recapitulation, also performing a survey of the structural content of the Protein Data Bank, of the milestones achieved over the years in the characterization of cross-β assemblies involved in the insurgence of neurodegenerative diseases. A particular emphasis is given to the very recent successful elucidation of amyloid-like aggregates characterized by remarkable molecular and structural complexities. We also review the state of the art of the structural characterization of cross-β based biomaterials by highlighting the benefits of the osmosis of information between these two research areas. Finally, we underline the new promising perspectives that recent successful characterizations of disease-related amyloid-like assemblies can open in the biomaterial field.

Novel imino- and aryl-sulfonate based photoacid generators for the cationic ring-opening polymerization of ε-caprolactone

The use of photoacid generators for the ring opening polymerization of cyclic esters is investigated.

Rapid High-Resolution Visible Light 3D Printing

Light-driven 3D printing to convert liquid resins into solid objects (i.e., photocuring) has traditionally been dominated by engineering disciplines, yielding the fastest build speeds and highest resolution of any additive manufacturing process. However, the reliance on high-energy UV/violet light limits the materials scope due to degradation and attenuation (e.g., absorption and/or scattering). Chemical innovation to shift the spectrum into more mild and tunable visible wavelengths promises to improve compatibility and expand the repertoire of accessible objects, including those containing biological compounds, nanocomposites, and multimaterial structures. Photochemistry at these longer wavelengths currently suffers from slow reaction times precluding its utility. Herein, novel panchromatic photopolymer resins were developed and applied for the first time to realize rapid high-resolution visible light 3D printing. The combination of electron-deficient and electron-rich coinitiators was critical to overcoming the speed-limited photocuring with visible light. Furthermore, azo-dyes were identified as vital resin components to confine curing to irradiation zones, improving spatial resolution. A unique screening method was used to streamline optimization (e.g., exposure time and azo-dye loading) and correlate resin composition to resolution, cure rate, and mechanical performance. Ultimately, a versatile and general visible-light-based printing method was shown to afford (1) stiff and soft objects with feature sizes <100 μm, (2) build speeds up to 45 mm/h, and (3) mechanical isotropy, rivaling modern UV-based 3D printing technology and providing a foundation from which bio- and composite-printing can emerge.

Materials Testing for the Development of Biocompatible Devices through Vat-Polymerization 3D Printing

Light-based 3D printing techniques could be a valuable instrument in the development of customized and affordable biomedical devices, basically for high precision and high flexibility in terms of materials of these technologies. However, more studies related to the biocompatibility of the printed objects are required to expand the use of these techniques in the health sector. In this work, 3D printed polymeric parts are produced in lab conditions using a commercial Digital Light Processing (DLP) 3D printer and then successfully tested to fabricate components suitable for biological studies. For this purpose, different 3D printable formulations based on commercially available resins are compared. The biocompatibility of the 3D printed objects toward A549 cell line is investigated by adjusting the composition of the resins and optimizing post-printing protocols; those include washing in common solvents and UV post-curing treatments for removing unreacted and cytotoxic products. It is noteworthy that not only the selection of suitable materials but also the development of an adequate post-printing protocol is necessary for the development of biocompatible devices.

100th Anniversary of Macromolecular Science Viewpoint: Integrating Chemistry and Engineering to Enable Additive Manufacturing with High-Performance Polymers

Additive manufacturing (AM) with high-performance polymers (HPPs) represents simultaneously one of the most desirable and challenging feats in the AM arena. The very properties that make HPPs so attractive in a broad range of applications also make them nearly impossible to process using common AM equipment. Furthermore, when AM is achieved, it often brings the caveat of compromised mechanical properties of the final parts, in comparison with those made via injection molding. The demand to have advanced fabrication methods, rapid prototyping, and customization of parts while maintaining high performance in the finished products has inspired creative innovations that integrate chemical synthesis, materials science, mechanical engineering, and other fields into a multidisciplinary approach to advance AM with the seemingly "unprintable" HPPs. In this Viewpoint, we summarize several standout developments in the area and offer our perspective on future directions and challenges.

Hierarchical ordering in light-triggered additive manufacturing

Herein, recent developments in the 3D printing of materials with structural hierarchy and their future prospects are reviewed. It is shown that increasing the extent of ordering, is essential to access novel properties and functionalities.