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

Synthesis of Photoresponsive Fast Self-healing Polyolefin Composites by Nickel-Catalyzed Copolymerization of Ethylene and Lignin Cluster Monomers

Polymers may suffer from sudden mechanical damages during long-term use under various harsh operating environments. Rapid and real-time self-healing will extend their service life, which is particularly attractive in the context of circular economy. In this work, a lignin cluster polymerization strategy (LCPS) was designed to prepare a series of lignin functionalized polyolefin composites with excellent mechanical properties through nickel catalyzed copolymerization of ethylene and lignin cluster monomers. These composites can achieve rapid self-healing within 30 seconds under a variety of extreme usage environments (underwater, seawater, extremely low temperatures as low as -60 °C, organic solvents, acid/alkali solvents, etc.), which is of great significance for real-time self-healing of sudden mechanical damage. More importantly, the dynamic cross-linking network within these composites enable great re-processability and amazing sealing performances.

New Advances in Covalent Network Polymers via Dynamic Covalent Chemistry

Covalent network polymers, as materials composed of atoms interconnected by covalent bonds in a continuous network, are known for their thermal and chemical stability. Over the past two decades, these materials have undergone significant transformations, gaining properties such as malleability, environmental responsiveness, recyclability, crystallinity, and customizable porosity, enabled by the development and integration of dynamic covalent chemistry (DCvC). In this review, we explore the innovative realm of covalent network polymers by focusing on the recent advances achieved through the application of DCvC. We start by examining the history and fundamental principles of DCvC, detailing its inception and core concepts and noting its key role in reversible covalent bond formation. Then the reprocessability of covalent network polymers enabled by DCvC is thoroughly discussed, starting from the significant milestones that marked the evolution of these polymers and progressing to their current trends and applications. The influence of DCvC on the crystallinity of covalent network polymers is then reviewed, covering their bond diversity, synthesis techniques, and functionalities. In the concluding section, we address the current challenges faced in the field of covalent network polymers and speculates on potential future directions.

Connecting Molecular Exchange Dynamics to Stress Relaxation in Phase-Separated Dynamic Covalent Networks

A suite of phase separated dynamic covalent networks based on highly tunable dynamic benzalcyanoacetate (BCA) thia-Michael acceptors are investigated. In situ kinetic studies on small molecule model systems are used in conjunction with macroscopic characterization of phase stability and stress relaxation to understand how the molecular dynamics relate to relaxation modes. Electronic modification of the BCA unit strongly impacts the exchange dynamics (particularly the rate of dissociation) and the overall equilibrium constant (Keq) of the system, with electron-withdrawing groups leading to decreased dissociation rate and increased Keq. Critically, below a chemistry-defined temperature cutoff (related to the stability of the hard phase domains), the stress relaxation behavior of these phase separated materials is dominated by the molecular exchange dynamics, allowing for networks with a tailored thermomechanical response.

3D printing of self-healing personalized liver models for surgical training and preoperative planning

3D printing can produce intuitive, precise, and personalized anatomical models, providing invaluable support for precision medicine, particularly in areas like surgical training and preoperative planning. However, conventional 3D printed models are often significantly more rigid than human organs and cannot undergo repetitive resection, which severely restricts their clinical value. Here we report the stereolithographic 3D printing of personalized liver models based on physically crosslinked self-healing elastomers with liver-like softness. Benefiting from the short printing time, the highly individualized models can be fabricated immediately following enhanced CT examination. Leveraging the high-efficiency self-healing performance, these models support repetitive resection for optimal trace through a trial-and-error approach. At the preliminary explorative clinical trial (NCT06006338), a total of 5 participants are included for preoperative planning. The primary outcomes indicate that the negative surgery margins are achieved and the unforeseen injuries of vital vascular structures are avoided. The 3D printing of liver models can enhance the safety of hepatic surgery, demonstrating promising application value in clinical practice.

Research Progress of Self-Healing Polymer for Ultraviolet-Curing Three-Dimensional Printing

Ultraviolet (UV)-curing technology as a photopolymerization technology has received widespread attention due to its advantages of high efficiency, wide adaptability, and environmental friendliness. Ultraviolet-based 3D printing technology has been widely used in the printing of thermosetting materials, but the permanent covalent cross-linked networks of thermosetting materials which are used in this method make it hard to recover the damage caused by the printing process through reprocessing, which reduces the service life of the material. Therefore, introducing dynamic bonds into UV-curable polymer materials might be a brilliant choice which can enable the material to conduct self-healing, and thus meet the needs of practical applications. The present review first introduces photosensitive resins utilizing dynamic bonds, followed by a summary of various types of dynamic bonds approaches. We also analyze the advantages/disadvantages of diverse UV-curable self-healing polymers with different polymeric structures, and outline future development trends in this field.

Thermally Responsive Selenide-containing Materials Based on Transalkylation of Selenonium Salts

Covalent adaptable networks (CANs) possess unique properties as a result of their internal dynamic bonds, such as self-healing and reprocessing abilities. In this study, we report a thermally responsive C-Se dynamic covalent chemistry (DCC) that relies on the transalkylation exchange between selenonium salts and selenides, which undergo a fast transalkylation reaction in the absence of any catalyst. Additionally, we demonstrate the presence of a dissociative mechanism in the absence of selenide groups. After incorporation of this DCC into selenide-containing polymer materials, it was observed that the cross-linked networks display varying dynamic exchange rates when using different alkylation reagents, suggesting that the reprocessing capacity of selenide-containing materials can be regulated. Also, by incorporating selenonium salts into polymer materials, we observed that the materials exhibited good healing ability at elevated temperatures as well as excellent solvent resistance at ambient temperature. This novel dynamic covalent chemistry thus provides a straightforward method for the healing and reprocessing of selenide-containing materials.

Stretchable, recyclable thermosets via photopolymerization and 3D printing of hemiacetal ester-based resins

Achieving a circular plastics economy is one of our greatest environmental challenges, yet conventional mechanical recycling remains inadequate for thermoplastics and incompatible with thermosets. The next generation of plastic materials will be designed with the capacity for degradation and recycling at end-of-use. To address this opportunity in the burgeoning technologies of 3D printing and photolithography, we report a modular system for the production of degradable and recyclable thermosets via photopolymerization. The polyurethane backbone imparts robust, elastic, and tunable mechanical properties, while the use of hemiacetal ester linkages allows for facile degradation under mild acid. The synthetic design based on hemiacetal esters enables simple purification to regenerate a functional polyurethane diol.

Self-Healing Polymeric Materials and Composites for Additive Manufacturing

Self-healing polymers have received widespread attention due to their ability to repair damage autonomously and increase material stability, reliability, and economy. However, the processability of self-healing materials has yet to be studied, limiting the application of rich self-healing mechanisms. Additive manufacturing effectively improves the shortcomings of conventional processing while increasing production speed, accuracy, and complexity, offering great promise for self-healing polymer applications. This article summarizes the current self-healing mechanisms of self-healing polymers and their corresponding additive manufacturing methods, and provides an outlook on future developments in the field.

Acoustodynamic Covalent Materials Engineering for the Remote Control of Physical Properties Inside Materials

Advances in vat photopolymerization (VP) 3D printing (3DP) technology enable the production of highly precise 3D objects. However, it is a major challenge to create dynamic functionalities and to manipulate the physical properties of the inherently insoluble and infusible cross-linked material generated from VP-3DP without reproduction. The fabrication of light- and high-intensity focused ultrasound (HIFU)-responsive cross-linked polymeric materials linked with hexaarylbiimidazole (HABI) in polymer chains based on VP-3DP is reported here. Although the photochemistry of HABI produces triphenylimidazolyl radicals (TPIRs) during the process of VP-3DP, the orthogonality of the photochemistry of HABI and photopolymerization enables the introduction of reversible cross-links derived from HABIs in the resulting 3D-printed objects. While photostimulation cleaves a covalent bond between two imidazoles in HABI to generate TPIRs only near the surface of the 3D-printed objects, HIFU triggers cleavage in the interior of materials. In addition, HIFU travels beyond an obstacle to induce a response of HABI-embedded cross-linked polymers, which cannot be attainable with photostimulation. The present system would be beneficial for tuning the physical properties and recycling of various polymeric materials, but it will also open the door for pinpoint modification, healing, and reshaping of materials when coupled to various dynamic covalent materials.

3D printing of dynamic covalent polymer network with on-demand geometric and mechanical reprogrammability

Delicate geometries and suitable mechanical properties are essential for device applications of polymer materials. 3D printing offers unprecedented versatility, but the geometries and mechanical properties are typically fixed after printing. Here, we report a 3D photo-printable dynamic covalent network that can undergo two independently controllable bond exchange reactions, allowing reprogramming the geometry and mechanical properties after printing. Specifically, the network is designed to contain hindered urea bonds and pendant hydroxyl groups. The homolytic exchange between hindered urea bonds allows reconfiguring the printed shape without affecting the network topology and mechanical properties. Under different conditions, the hindered urea bonds are transformed into urethane bonds via exchange reactions with hydroxyl groups, which permits tailoring of the mechanical properties. The freedom to reprogram the shape and properties in an on-demand fashion offers the opportunity to produce multiple 3D printed products from one single printing step.

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.

Intrinsically Self-Healing Polymers: From Mechanistic Insight to Current Challenges

Self-healing materials open new prospects for more sustainable technologies with improved material performance and devices' longevity. We present an overview of the recent developments in the field of intrinsically self-healing polymers, the broad class of materials based mostly on polymers with dynamic covalent and noncovalent bonds. We describe the current models of self-healing mechanisms and discuss several examples of systems with different types of dynamic bonds, from various hydrogen bonds to dynamic covalent bonds. The recent advances indicate that the most intriguing results are obtained on the systems that have combined different types of dynamic bonds. These materials demonstrate high toughness along with a relatively fast self-healing rate. There is a clear trade-off relationship between the rate of self-healing and mechanical modulus of the materials, and we propose design principles of polymers toward surpassing this trade-off. We also discuss various applications of intrinsically self-healing polymers in different technologies and summarize the current challenges in the field. This review intends to provide guidance for the design of intrinsic self-healing polymers with required properties.

Digital light 3D printing of a polymer composite featuring robustness, self-healing, recyclability and tailorable mechanical properties

Producing lightweight structures with high weight-specific strength and stiffness, self-healing abilities, and recyclability, is highly attractive for engineering applications such as aerospace, biomedical devices, and smart robots. Most self-healing polymer systems used to date for mechanical components lack 3D printability and satisfactory load-bearing capacity. Here, we report a new self-healable polymer composite for Digital Light Processing 3D Printing, by combining two monomers with distinct mechanical characteristics. It shows a desirable and superior combination of properties among 3D printable self-healing polymers, with tensile strength and elastic modulus up to 49 MPa and 810 MPa, respectively. Benefiting from dual dynamic bonds between the linear chains, a healing efficiency of above 80% is achieved after heating at a mild temperature of 60 °C without additional solvents. Printed objects are also endowed with multi-materials assembly and recycling capabilities, allowing robotic components to be easily reassembled or recycled after failure. Mechanical properties and deformation behaviour of printed composites and lattices can be tuned significantly to suit various practical applications by altering formulation. Lattice structures with three different architectures were printed and tested in compression: honeycomb, re-entrant, and chiral. They can regain their structural integrity and stiffness after damage, which is of great value for robotic applications. This study extends the performance space of composites, providing a pathway to design printable architected materials with simultaneous mechanical robustness/healability, efficient recoverability, and recyclability.

Ethylene-Vinyl Acetate Copolymers as Potential Thermoplastic Modifiers of Photopolymer Compositions

The possibility of using thermoplastic polymers in photopolymer compositions for SLA and DLP is discussed in this article. The diffusion and mutual solubility of uncured systems based on tert-butyl acrylate (tBA) and ethylene-vinyl acetate copolymers (EVA) or low-density polyethylene (LDPE) were studied. The solubility and diffusion of tBA with EVA containing 7, 20, and 40 wt.% vinyl acetate (VA) and with LDPE in the temperature range 20-75 °C were studied by optical micro-interferometry method. Phase diagrams of LDPE-tBA, EVA-7-tBA, and EVA-20-tBA systems were obtained. It is shown that the compositions are characterized by the phase-state diagrams of amorphous separation with the upper critical solution temperature (UCST). The concentration dependences of the interdiffusion coefficients as well as dependences of the self-diffusion coefficients on VA content and on temperature were plotted. The activation energy of self-diffusion of EVA and LDPE was calculated. It was shown that the most promising tBA modifier is EVA-40, which is completely soluble at all studied temperature ranges. The obtained data on the mixing of the initial components is valuable for further studies of the processes of structure formation during photocuring of compositions, regulation of the phase structure and, as a consequence, the performance characteristics of the 3D printable materials.

Polymerization, Stimuli-induced Depolymerization, and Precipitation-driven Macrocyclization in a Nitroaldol Reaction System

Dynamic covalent polymers of different topology have been synthesized from an aromatic dialdehyde and α,ω-dinitroalkanes via the nitroaldol reaction. All dinitroalkanes yielded dynamers with the dialdehyde, where the length of the dinitroalkane chain played a vital role in determining the structure of the final products. For longer dinitroalkanes, linear dynamers were produced, where the degree of polymerization reached a plateau at higher feed concentrations. In the reactions involving 1,4-dinitrobutane and 1,5-dinitropentane, specific macrocycles were formed through depolymerization of the linear chains, further driven by precipitation. At lower temperature, the same systemic self-sorting effect was also observed for the 1,6-dinitrohexane-based dynamers. Moreover, the dynamers showed a clear adaptive behavior, displaying depolymerization and rearrangement of the dynamer chains in response to alternative building blocks as external stimuli.

A new trend of using poly(vinyl alcohol) in 3D and 4D printing technologies: Process and applications

Recently, 3D/4D printing technologies have been the researchers' interest, and they are getting improved more important. They are applicable in various fields like medical fields, pharmaceutics, construction, tissue engineering, dentistry, water treatment, etc. These technologies overcame the difficulty of the conventional methods in producing complicated structures. They can be fed by different materials such as nanomaterials, smart polymers, responsive polymers, metamaterials, synthetic polymers, natural polymers, and so forth. One of the smart and stimuli-responsive polymers is poly(vinyl alcohol) (PVA). In addition to numerous applications of PVA like medicine, environmental fields, etc., researchers are showing a tendency to use PVA in 3D/4D printing technologies. The main reasons for PVA's increased interest in 3D/4D printing technologies are suitable flowability, stimuli-responsivity, extrudability, biocompatibility, biodegradability, cost-effectiveness, and other features. This review aims to introduce the 3D/4D printing technologies' knowledge and then the applications of PVA as a feed in these novel technologies.

Thermally Driven Diselenide Metathesis: Polarization Process vs Radical Process

Diselenide, as a dynamic covalent bond, has been widely applied in functional materials due to its response to light, heat, sonication, pH, and other stimuli. Herein, a polarization-induced metathesis mechanism for diselenides under heating conditions in the dark is proposed. First, a radical trap experiment is used to prove that the exchange reaction of diselenides in the dark does not involve any radicals. Second, the dynamic exchange reaction of diselenides is found to be affected not only by the polarity of the solvent but also by the introduction of polar groups into the molecular skeleton. Furthermore, DFT calculations also support the notion that polarity has a large effect on the heterolytic rather than homolytic bond dissociation energies. The experimental results for allyl selenide small molecules, polymers, and polymer materials catalyzed by diselenide all support the polarization-induced metathesis mechanism. In short, we successfully enhanced the understanding of the mechanism for diselenide metathesis.

Visible Light Chemical Micropatterning Using a Digital Light Processing Fluorescence Microscope

Patterning chemical reactivity with a high spatiotemporal resolution and chemical versatility is critically important for advancing revolutionary emergent technologies, including nanorobotics, bioprinting, and photopharmacology. Current methods are complex and costly, necessitating novel techniques that are easy to use and compatible with a wide range of chemical functionalities. This study reports the development of a digital light processing (DLP) fluorescence microscope that enables the structuring of visible light (465-625 nm) for high-resolution photochemical patterning and simultaneous fluorescence imaging of patterned samples. A range of visible-light-driven photochemical systems, including thiol-ene photoclick reactions, Wolff rearrangements of diazoketones, and photopolymerizations, are shown to be compatible with this system. Patterning the chemical functionality onto microscopic polymer beads and films is accomplished with photographic quality and resolutions as high as 2.1 μm for Wolff rearrangement chemistry and 5 μm for thiol-ene chemistry. Photoactivation of molecules in living cells is demonstrated with single-cell resolution, and microscale 3D printing is achieved using a polymer resin with a 20 μm xy-resolution and a 100 μm z-resolution. Altogether, this work debuts a powerful and easy-to-use platform that will facilitate next-generation nanorobotic, 3D printing, and metamaterial technologies.

Diels–Alder Cycloadditions of Bio-Derived Furans with Maleimides as a Sustainable «Click» Approach towards Molecular, Macromolecular and Hybrid Systems

This mini-review highlights the recent research trends in designing organic or organic-inorganic hybrid molecular, biomolecular and macromolecular systems employing intermolecular Diels–Alder cycloadditions of biobased, furan-containing substrates and maleimide dienophiles. The furan/maleimide Diels–Alder reaction is a well-known process that may proceed with high efficiency under non-catalytic and solvent-free conditions. Due to the simplicity, 100% atom economy and biobased nature of many furanic substrates, this type of [4+2]-cycloaddition may be recognized as a sustainable “click” approach with high potential for application in many fields, such as fine organic synthesis, bioorganic chemistry, material sciences and smart polymers development.

A Photoinduced Dual-Wavelength Approach for 3D Printing and Self-Healing of Thermosetting Materials

Vat photopolymerization-based 3D printing techniques have been widely used to produce high-resolution 3D thermosetting materials. However, the lack of repairability of these thermosets leads to the production of waste. In this study, reversible addition fragmentation chain transfer (RAFT) agents are incorporated into resin formulations to allow visible light (405 nm) mediated 3D printing of materials with self-healing capabilities. The self-healing process is based on the reactivation of RAFT agent embedded in the thermosets under UV light (365 nm), which enables reformation of the polymeric network. The self-healing process can be performed at room temperature without prior deoxygenation. The impact of the type and concentration of RAFT agents in the polymer network on the healing efficiency is explored. Resins containing RAFT agents enable 3D printing of thermosets with self-healing properties, broadening the scope of future applications for polymeric thermosets in various fields.

Dissociative Carbamate Exchange Anneals 3D Printed Acrylates

Relative to other additive manufacturing modalities, vat photopolymerization (VP) offers designers superior surface finish, feature resolution, and throughput. However, poor interlayer network formation can limit a VP-printed part's tensile strength along the build axis. We demonstrate that the incorporation of carbamate bonds capable of undergoing dissociative exchange reactions provides improved interlayer network formation in VP-printed urethane acrylate polymers. In the presence of dibutyltin dilaurate catalyst, the exchange of these carbamate bonds enables rapid stress relaxation with an activation energy of 133 kJ/mol, consistent with a dissociative bond exchange process. Annealed XY tensile samples containing a catalyst demonstrate a 25% decrease in Young's modulus, attributed to statistical changes in network topology, while samples without a catalyst show no observable effect. Annealed ZX tensile samples printed with layers perpendicular to tensile load demonstrate an increase in elongation at break, indicative of self-healing. The strain at break for samples containing a catalyst increases from 33.9 to 56.0% after annealing but decreases from 48.1 to 32.1% after annealing in samples without a catalyst. This thermally activated bond exchange process improves the performance of VP-printed materials via self-healing across layers and provides a means to change Young's modulus after printing. Thus, the incorporation of carbamate bonds and appropriate catalysts in the VP-printing process provides a robust platform for enhancing material properties and performance.

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.