Polymerizations in Continuous Flow: Recent Advances in the Synthesis of Diverse Polymeric Materials

Sequence-Defined Synthesis Enabled by Fast and Living Anionic Monoaddition of Vinyl Monomers

The selective monoaddition of polymerizable vinyl monomers like styrenes and methacrylates in a living manner has been achieved for the flash-flow preparation of molecules in a defined sequence with high selectivity. We demonstrated the sequence-defined synthesis of multifunctional molecules using an initiator, functionalized styrenes, diarylethylenes, various methacrylates, and an electrophilic trapping reagent at the living terminus (six-component sequential connection at maximum) without any intermediate purification steps. The anionic living terminus of the vinyl monomers in the flow system described herein is active for polymerization, such that the styrene or methacrylate sequence can be expanded to afford highly dispersed oligomers without affecting other single units, which means that the unequivocal sequences were successfully inserted into the internal or terminal positions. The methodology described herein provides an adaptable method for the construction of new molecular spaces based on unimolecular sequence control and pinpoint functionalization.

Scalable and Precise Synthesis of Structurally Colored Bottlebrush Block Copolymers: Enabling Refined Color Calibration for Sustainable Photonic Pigments

Self-assembled bottlebrush block copolymers (BBCPs) offer a vibrant, eco-friendly alternative to traditional toxic pigments and dyes, providing vivid structural colors with significantly reduced environmental impact. Scaling up the synthesis of these polymers for practical applications has been challenging with conventional batch methods, which suffer from slow mass and heat transfer, inadequate mixing, and issues with reproducibility. Precise control over molecular weight and dispersity remains a significant challenge for achieving finely tuned color appearances. Here, we present an alternative strategy to overcome the challenges by integrating a rapid continuous flow technique with an in-line self-assembly procedure. This strategy enables the rapid, stable and large-scale synthesis of narrow-dispersed BBCPs, exceeding 2 kg/day, a significant improvement over conventional gram-scale methods. Furthermore, precise control over the degree of polymerization is achieved with an unprecedented interval accuracy of four repeat units. This level of precision enables refined color calibration in the resulting photonic pigments, effectively eliminating the need for labor-intensive and costly multiple batch syntheses.

Transforming science labs into automated factories of discovery

Laboratories in chemistry, biochemistry, and materials science are at the leading edge of technology, discovering molecules and materials to unlock capabilities in energy, catalysis, biotechnology, sustainability, electronics, and more. Yet, most modern laboratories resemble factories from generations past, with a large reliance on humans manually performing synthesis and characterization tasks. Robotics and automation can enable scientific experiments to be conducted faster, more safely, more accurately, and with greater reproducibility, allowing scientists to tackle large societal problems in domains such as health and energy on a shorter timescale. We define five levels of laboratory automation, from laboratory assistance to full automation. We also introduce robotics research challenges that arise when increasing levels of automation and when increasing the generality of tasks within the laboratory. Robots are poised to transform science labs into automated factories of discovery that accelerate scientific progress.

The Spatial Distribution of Lipophilic Cations in Gradient Copolymers Regulates Polymer-pDNA Complexation, Polyplex Aggregation, and Intracellular pDNA Delivery

Here, we demonstrate that the spatial distribution of lipophilic cations governs the complexation pathways, serum stability, and biological performance of polymer-pDNA complexes (polyplexes). Previous research focused on block/statistical copolymers, whereas gradient copolymers, where the density of lipophilic cations diminishes (gradually or steeply) along polymer backbones, remain underexplored. We engineered gradient copolymers that combine the polyplex colloidal stability of block copolymers with the transfection efficiency of statistical copolymers. We synthesized length- and compositionally equivalent gradient copolymers (G1-G3) along with statistical (S) and block (B) copolymers of 2-(diisopropylamino)ethyl methacrylate and 2-hydroxyethyl methacrylate. We mapped how polymer microstructure governs pDNA loading per polyplex, pDNA conformational changes, and polymer-pDNA binding thermodynamics via static light scattering, circular dichroism spectroscopy, and isothermal titration calorimetry, respectively. While gradient steepness is a powerful design handle to improve polyplex physical properties, augment pDNA delivery capacity, and attenuate polycation-triggered hemolysis, microstructural contrasts did not elicit differences in complement activation.

Truxinates and truxillates: building blocks for architecturally complex polymers and advanced materials

Significant advancements in the syntheses of cyclobutane containing small molecules and polymers are described in the last 15 years. Small molecule cyclobutanes are under investigation for their diverse pharmacological activities, while polymers with cyclobutane backbones are emerging as novel mechanophores, stress-responsive materials, and sustainable plastics. Within these chemistries, [2 + 2] photocycloadditions to yield truxinates and truxillates are highly efficient offering a versatile strategy to access complex scaffolds. This article provides a comprehensive review on the synthetic methodologies, properties, and applications of polymer truxinates and truxillates, providing the background necessary to understand current developments and envision future applications. Additionally, we highlight the links between the development, discoveries, and synthetic methodologies of small molecules and cyclobutane polymers. We emphasize structure property relationships and discuss methods to control composition and structure for desired applications. We begin with a discussion of synthetic techniques for small molecule and polymer cyclobutanes followed by their greater applications, including pharmacological and material properties with examples including sustainable plastics and stimuli-responsive systems.

Visible light photoflow synthesis of a Cu(ii) single-chain polymer nanoparticle catalyst

We herein pioneer the visible light (λ max = 410 nm) mediated flow synthesis of catalytically active single-chain nanoparticles (SCNPs). Our design approach is based on a copolymer of poly(ethylene glycol) methyl ether methacrylate and a photocleavable 2-((((2-nitrobenzyl)oxy)carbonyl)amino)ethyl methacrylate monomer which can liberate amine groups upon visible light irradiation, allowing for single-chain collapse via the complexation of Cu(ii) ions. We initially demonstrate the successful applicability of our design approach for the batch photochemical synthesis of Cu(ii) SCNPs and transfer the concept to photoflow conditions, enabling, for the first time, the continuous production of functional SCNPs. Critically, we explore their ability to function as a photocatalyst for the cleavage of carbon-carbon single and double bonds on the examples of xanthene-9-carboxylic acid and oleic acid, demonstrating the advantageous effect SCNPs can provide over analogous small molecule catalysts.

Bottlebrush Polyethylene Glycol Nanocarriers Translocate across Human Airway Epithelium via Molecular Architecture-Enhanced Endocytosis

Pulmonary drug delivery is critical for the treatment of respiratory diseases. However, the human airway surface presents multiple barriers to efficient drug delivery. Here, we report a bottlebrush poly(ethylene glycol) (PEG-BB) nanocarrier that can translocate across all barriers within the human airway surface. Guided by a molecular theory, we design a PEG-BB molecule consisting of a linear backbone densely grafted by many (∼1000) low molecular weight (∼1000 g/mol) polyethylene glycol (PEG) chains; this results in a highly anisotropic, wormlike nanocarrier featuring a contour length of ∼250 nm, a cross-section of ∼20 nm, and a hydrodynamic diameter of ∼40 nm. Using the classic air-liquid-interface culture system to recapitulate essential biological features of the human airway surface, we show that PEG-BB rapidly penetrates through endogenous airway mucus and periciliary brush layer (mesh size of 20-40 nm) to be internalized by cells across the whole epithelium. By quantifying the cellular uptake of polymeric carriers of various molecular architectures and manipulating cell proliferation and endocytosis pathways, we show that the translocation of PEG-BB across the epithelium is driven by bottlebrush architecture-enhanced endocytosis. Our results demonstrate that large, wormlike bottlebrush PEG polymers, if properly designed, can be used as a carrier for pulmonary and mucosal drug delivery.

Continuous flow synthesis and post-synthetic conversion of single-crystalline covalent organic frameworks

The synthesis and scale-up of high quality covalent organic frameworks (COFs) remains a challenge due to slow kinetics of the reversible bond formation and the need for precise control of reaction conditions. Here we report the rapid synthesis of faceted single crystals of two-dimensional (2D) COFs using a continuous flow reaction process. Two imine linked materials were polymerized to the hexagonal CF-TAPB-DMPDA and the rhombic CF-TAPPy-PDA COF, respectively. The reaction conditions were optimized to produce single crystals of micrometer size, which notably formed when the reaction was cooling to room temperature. This indicated a growth mechanism consistent with the fusion of smaller COF particles. The optimized conditions were used to demonstrate the scalability of the continuous approach by synthesizing high quality, faceted COFs at a rate of more than 1 g h-1. The materials showed high crystallinity and porosity with surface areas exceeding 2000 m2 g-1. Additionally, the versatility of the continuous flow reaction approach was demonstrated on a post-synthetic single crystal to single crystal demethylation of CF-TAPB-DMPDA to afford a hydroxyl functionalized COF CF-TAPB-DHPDA. Throughout the modification process, the material maintained its hexagonal morphology, crystallinity, and porosity. This work reports the first example of synthesizing and post-synthetically modifying imine linked COF single crystals in continuous flow and will prove a first step towards scaling high quality COFs to industrial levels.

Continuous Flow Synthesis of Functional Isocyanate-Free Poly(oxazolidone)s by Step-Growth Polymerization

Flow chemistry presents many advantages over batch processes for the fast and continuous production of polymers under more robust, safer, and easily scalable conditions. Although largely exploited for chain-growth polymerizations, it has rarely been applied to step-growth polymerizations (SGP) due to their inherent limitations. Here, we report the facile and fast preparation of an emerging class of nonisocyanate polyurethanes, i.e., CO2-based poly(oxazolidone)s, by SGP in continuous flow reactors. Importantly, we also demonstrate that functional poly(oxazolidone)s are easily prepared by telescoping a flow module where SGP occurs with reagents able to simultaneously promote two polymer derivatizations in a second module, i.e., dehydration followed by cationic thiol-ene to yield poly(N,S-acetal oxazolidone)s. The functional polymer is produced at a high rate and functionalization degree, without requiring the isolation of any intermediates. This work demonstrates the enormous potential of flow technology for the facile and fast continuous production of functional polymers by SGP.

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

High-Precision Tailored Polymer Molecular Weights for Specific Photovoltaic Applications through Ultrasound-Induced Simultaneous Physical and Chemical Events

It is highly challenging to reproducibly prepare semiconducting polymers with targeted molecular weight tailored for next-generation photovoltaic applications. Once such an easily accessible methodology is established, which can not only contribute to overcome the current limitation of the statistically determined nature of semiconducting polymers, but also facilitate rapid incorporation into the broad synthetic chemists' toolbox. Here, we describe a simple yet robust ultrasonication-assisted Stille polymerization for accessing semiconducting polymers with high-precision tailored molecular weights (from low to ultrahigh molecular weight ranges) while mitigating their interbatch variations. We propose that ultrasound-induced simultaneous physical and chemical events enable precise control of the semiconducting polymers' molecular weights with high reproducibility to satisfy all the optical/electrical and morphological demands of diverse types of high-performance semiconducting polymer-based devices; as demonstrated in in-depth experimental screenings in applications of both organic and perovskite photovoltaics. We believe that this methodology provides a fast development of new and existing semiconducting polymers with the highest-level performances possible on various photovoltaic devices.

Toward Biomass-Based Organic Electronics: Continuous Flow Synthesis and Electropolymerization of N-Substituted Pyrroles

Pyrroles are foundational building blocks in a wide array of disciplines, including chemistry, pharmaceuticals, and materials science. Currently sourced from nonrenewable fossil sources, there is a strive to explore alternative and sustainable synthetic pathways to pyrroles utilizing renewable feedstocks. The utilization of biomass resources presents a compelling solution, particularly given that several key bulk and fine chemicals already originate from biomass. For instance, 2,5-dimethoxytetrahydrofuran and aniline are promising candidates for biomass-based chemical production. In this study, we present an innovative approach for synthesizing N-substituted pyrroles by modifying the Clauson-Kaas protocol, starting from 2,5-dimethoxytetrahydrofuran as the precursor. The developed methodology offers the advantage of producing pyrroles under mild reaction conditions with the potential for catalyst-free reactions depending upon the structural features of the substrate. We devised protocols suitable for both continuous flow and batch reactions, enabling the conversion of a wide range of anilines and sulfonamides into their respective N-substituted pyrroles with good to excellent yields. Moreover, we demonstrate the feasibility of depositing thin films of the corresponding polymers onto electrodes through in situ electropolymerization. This innovative application showcases the potential for sustainable, biomass-based organic electronics, thus, paving the way for environmentally friendly advancements in this field.

Data-Driven Design of Polymer-Based Biomaterials: High-throughput Simulation, Experimentation, and Machine Learning

Polymers, with the capacity to tunably alter properties and response based on manipulation of their chemical characteristics, are attractive components in biomaterials. Nevertheless, their potential as functional materials is also inhibited by their complexity, which complicates rational or brute-force design and realization. In recent years, machine learning has emerged as a useful tool for facilitating materials design via efficient modeling of structure-property relationships in the chemical domain of interest. In this Spotlight, we discuss the emergence of data-driven design of polymers that can be deployed in biomaterials with particular emphasis on complex copolymer systems. We outline recent developments, as well as our own contributions and takeaways, related to high-throughput data generation for polymer systems, methods for surrogate modeling by machine learning, and paradigms for property optimization and design. Throughout this discussion, we highlight key aspects of successful strategies and other considerations that will be relevant to the future design of polymer-based biomaterials with target properties.

Enhancing the Scalability of Crystallization-Driven Self-Assembly Using Flow Reactors

Anisotropic materials have garnered significant attention due to their potential applications in cargo delivery, surface modification, and composite reinforcement. Crystallization-driven self-assembly (CDSA) is a practical way to access anisotropic structures, such as 2D platelets. Living CDSA, where platelets are formed by using seed particles, allows the platelet size to be well controlled. Nonetheless, the current method of platelet preparation is restricted to low concentrations and small scales, resulting in inefficient production, which hampers its potential for commercial applications. To address this limitation, continuous flow reactors were employed to improve the production efficiency. Flow platforms ensure consistent product quality by maintaining the same parameters throughout the process, circumventing batch-to-batch variations and discrepancies observed during scale-up. In this study, we present the first demonstration of living CDSA performed within flow reactors. A continuous flow system was established, and the epitaxial growth of platelets was initially conducted to study the influence of flow parameters such as temperature, residence time, and flow rate on the morphology of platelets. Comparison of different epitaxial growth manners of seeds and platelets was made when using seeds to perform living CDSA. Size-controllable platelets from seeds can be obtained from a series flow system by easily tuning flow rates. Additionally, uniform platelets were continuously collected, exhibiting improved size and dispersity compared to those obtained in batch reactions.

Navigating the Expansive Landscapes of Soft Materials: A User Guide for High-Throughput Workflows

Synthetic polymers are highly customizable with tailored structures and functionality, yet this versatility generates challenges in the design of advanced materials due to the size and complexity of the design space. Thus, exploration and optimization of polymer properties using combinatorial libraries has become increasingly common, which requires careful selection of synthetic strategies, characterization techniques, and rapid processing workflows to obtain fundamental principles from these large data sets. Herein, we provide guidelines for strategic design of macromolecule libraries and workflows to efficiently navigate these high-dimensional design spaces. We describe synthetic methods for multiple library sizes and structures as well as characterization methods to rapidly generate data sets, including tools that can be adapted from biological workflows. We further highlight relevant insights from statistics and machine learning to aid in data featurization, representation, and analysis. This Perspective acts as a "user guide" for researchers interested in leveraging high-throughput screening toward the design of multifunctional polymers and predictive modeling of structure-property relationships in soft materials.

Continuous generation of cross-linked polymer nanoparticles employing an ultrasonic microreactor

In this article, a new system employing an ultrasonic microreactor coupled with a tubular reactor is presented for the continuous generation of polymer nanoparticles. The continuous generation of cross-linked polymer nanoparticles utilizing the monomer butyl methacrylate and the cross-linker ethylene glycol dimethacrylate is demonstrated. Firstly, the miniemulsion polymerization of a monomer-in-water miniemulsion is studied in a batch system. Secondly, a coiled tubular reactor is employed for the continuous polymerization of the miniemulsion generated by an ultrasonic microreactor. Finally, the influence of monomer volume fraction and surfactant concentration on the synthesized polymer nanoparticles is studied. Polymer particles in a size range of 50-250 nm are synthesized and a high polymerization conversion is achieved utilizing the system demonstrated in this article.

Flow Optimization of Photoredox-Mediated Metal-Free Ring-Opening Metathesis Polymerization

Photoredox-mediated metal-free ring-opening metathesis polymerization (MF-ROMP) is a convenient metal-free method to produce a variety of ROMP polymers. Transitioning MF-ROMP from a batch to a continuous flow process has yet to be demonstrated and could potentially benefit the production efficiency, safety, and modularity of reaction conditions. We designed and evaluated continuous flow and droplet flow setups and compared the results for MF-ROMP across a short series of common monomers. By using the droplet flow reactor setup, we achieved flow conversions comparable to that of batch and circumvented issues with diffusion-limited mixing and air exposure.

The Power of Automation in Polymer Chemistry: Precision Synthesis of Multiblock Copolymers with Block Sequence Control

Machines can revolutionize the field of chemistry and material science, driving the development of new chemistries, increasing productivity, and facilitating reaction scale up. The incorporation of automated systems in the field of polymer chemistry has however proven challenging owing to the demanding reaction conditions, rendering the automation setup complex and costly. There is an imminent need for an automation platform which uses fast and simple polymerization protocols, while providing a high level of control on the structure of macromolecules via precision synthesis. This work combines an oxygen tolerant, room temperature polymerization method with a simple liquid handling robot to automatically prepare precise and high order multiblock copolymers with unprecedented livingness even after many chain extensions. The highest number of blocks synthesized in such a system is reported, demonstrating the capabilities of this automated platform for the rapid synthesis and complex polymer structure formation.

Inverse Miniemulsion Enables the Continuous-Flow Synthesis of Controlled Ultra-High Molecular Weight Polymers

We report the controlled synthesis of ultra-high molecular weight (UHMW) polymers (Mn ≥ 106 g/mol) via continuous flow in a tubular reactor. At high monomer conversion, UHMW polymers in homogeneous batch polymerization exhibit high viscosities that pose challenges for employing continuous flow reactors. However, under heterogeneous inverse miniemulsion (IME) conditions, UHMW polymers can be produced within the dispersed phase, while the viscosity of the heterogeneous mixture remains approximately the same as the viscosity of the continuous phase. Conducting such IME polymerizations in flow results in a faster rate of polymerization compared to batch IME polymerizations while still providing excellent control over molecular weight up to 106 g/mol. Crucial emulsion parameters, such as particle size and stability under continuous flow conditions, were examined using dynamic light scattering. A range of poly(N,N-dimethylacrylamide) and poly(4-acryloylmorpholine) polymers with molecular weights of 104-106 g/mol (Đ ≤ 1.31) were produced by this method using water-soluble trithiocarbonates as photoiniferters.

Transfer Learning of Full Molecular Weight Distributions via High-Throughput Computer-Controlled Polymerization

The skew and shape of the molecular weight distribution (MWD) of polymers have a significant impact on polymer physical properties. Standard summary metrics statistically derived from the MWD only provide an incomplete picture of the polymer MWD. Machine learning (ML) methods coupled with high-throughput experimentation (HTE) could potentially allow for the prediction of the entire polymer MWD without information loss. In our work, we demonstrate a computer-controlled HTE platform that is able to run up to 8 unique variable conditions in parallel for the free radical polymerization of styrene. The segmented-flow HTE system was equipped with an inline Raman spectrometer and offline size exclusion chromatography (SEC) to obtain time-dependent conversion and MWD, respectively. Using ML forward models, we first predict monomer conversion, intrinsically learning varying polymerization kinetics that change for each experimental condition. In addition, we predict entire MWDs including the skew and shape as well as SHAP analysis to interpret the dependence on reagent concentrations and reaction time. We then used a transfer learning approach to use the data from our high-throughput flow reactor to predict batch polymerization MWDs with only three additional data points. Overall, we demonstrate that the combination of HTE and ML provides a high level of predictive accuracy in determining polymerization outcomes. Transfer learning can allow exploration outside existing parameter spaces efficiently, providing polymer chemists with the ability to target the synthesis of polymers with desired properties.

Quid Pro Flow

How do you get into flow? We trained in flow chemistry during postdoctoral research and are now applying it in new areas: materials chemistry, crystallization, and supramolecular synthesis. Typically, when researchers think of "flow", they are considering predominantly liquid-based organic synthesis; application to other disciplines comes with its own challenges. In this Perspective, we highlight why we use and champion flow technologies in our fields, summarize some of the questions we encounter when discussing entry into flow research, and suggest steps to make the transition into the field, emphasizing that communication and collaboration between disciplines is key.

A dual initiator approach for oxygen tolerant RAFT polymerization

Reversible-deactivation radical polymerizations are privileged approaches for the synthesis of functional and hybrid materials. A bottleneck for conducting these processes is the need to maintain oxygen free conditions. Herein we report a broadly applicable approach to "polymerize through" oxygen using the synergistic combination of two radical initiators having different rates of homolysis. The in situ monitoring of the concentrations of oxygen and monomer simultaneously provided insight into the function of the two initiators and enabled the identification of conditions to effectively remove dissolved oxygen and control polymerization under open-to-air conditions. By understanding how the surface area to volume ratio of reaction vessels influence open-to-air polymerizations, well-defined polymers were produced using acrylate, styrenic, and methacrylate monomers, which each represent an expansion of scope for the "polymerizing through" oxygen approach. Demonstration of this method in tubular reactors using continuous flow chemistry provided a more complete structure-reactivity understanding of how reaction headspace influences PTO RAFT polymerizations.

Multi-scale computer-aided design and photo-controlled macromolecular synthesis boosting uranium harvesting from seawater

By integrating multi-scale computational simulation with photo-regulated macromolecular synthesis, this study presents a new paradigm for smart design while customizing polymeric adsorbents for uranium harvesting from seawater. A dissipative particle dynamics (DPD) approach, combined with a molecular dynamics (MD) study, is performed to simulate the conformational dynamics and adsorption process of a model uranium grabber, i.e., PAOm-b-PPEGMAn, suggesting that the maximum adsorption capacity with atomic economy can be achieved with a preferred block ratio of 0.18. The designed polymers are synthesized using the PET-RAFT polymerization in a microfluidic platform, exhibiting a record high adsorption capacity of uranium (11.4 ± 1.2 mg/g) in real seawater within 28 days. This study offers an integrated perspective to quantitatively assess adsorption phenomena of polymers, bridging metal-ligand interactions at the molecular level with their spatial conformations at the mesoscopic level. The established protocol is generally adaptable for target-oriented development of more advanced polymers for broadened applications.

Materiomically Designed Polymeric Vehicles for Nucleic Acids: Quo Vadis?

Despite rapid advances in molecular biology, particularly in site-specific genome editing technologies, such as CRISPR/Cas9 and base editing, financial and logistical challenges hinder a broad population from accessing and benefiting from gene therapy. To improve the affordability and scalability of gene therapy, we need to deploy chemically defined, economical, and scalable materials, such as synthetic polymers. For polymers to deliver nucleic acids efficaciously to targeted cells, they must optimally combine design attributes, such as architecture, length, composition, spatial distribution of monomers, basicity, hydrophilic-hydrophobic phase balance, or protonation degree. Designing polymeric vectors for specific nucleic acid payloads is a multivariate optimization problem wherein even minuscule deviations from the optimum are poorly tolerated. To explore the multivariate polymer design space rapidly, efficiently, and fruitfully, we must integrate parallelized polymer synthesis, high-throughput biological screening, and statistical modeling. Although materiomics approaches promise to streamline polymeric vector development, several methodological ambiguities must be resolved. For instance, establishing a flexible polymer ontology that accommodates recent synthetic advances, enforcing uniform polymer characterization and data reporting standards, and implementing multiplexed in vitro and in vivo screening studies require considerable planning, coordination, and effort. This contribution will acquaint readers with the challenges associated with materiomics approaches to polymeric gene delivery and offers guidelines for overcoming these challenges. Here, we summarize recent developments in combinatorial polymer synthesis, high-throughput screening of polymeric vectors, omics-based approaches to polymer design, barcoding schemes for pooled in vitro and in vivo screening, and identify materiomics-inspired research directions that will realize the long-unfulfilled clinical potential of polymeric carriers in gene therapy.

Chemical Upcycling of Commercial Polystyrene via Catalyst-Controlled Photooxidation

Chemical upcycling of polystyrene into targeted small molecules is desirable to reduce plastic pollution. Herein, we report the upcycling of polystyrene to benzoyl products, primarily benzoic acid, using a catalyst-controlled photooxidative degradation method. FeCl₃ undergoes a homolytic cleavage upon irradiation with white light to generate a chlorine radical, abstracting an electron-rich hydrogen atom on the polymer backbone. Under the oxygen-rich environment, high MW polystyrene (>90 kg/mol) degrades down to <1 kg/mol and produces up to 23 mol % benzoyl products. A series of mechanistic studies showed that chlorine radicals promoted the degradation via hydrogen-atom abstraction. Commercial polystyrene degrades efficiently in our method, showing the compatibility of our system with polymer fillers. Finally, we demonstrated the potential of scaling up our approach in a photoflow process to convert gram quantities of PS to benzoic acid.

Free-radical polymerization of 2-hydroxyethyl methacrylate (HEMA) supported by the high electric field

In macromolecular science, tunning basic polymer parameters, like molecular weight (Mn) or molecular weight distribution (dispersity, Đ), is an active research topic. Many prominent synthetic protocols concerning chemical modification of...

Peter L, Chan C, Mikhailova T, Bexheti V, Kapadia A, Carbery WP, Ng K, Maity P. Microfluidic-Supported Synthesis of Anisotropic Polyvinyl Methacrylate Nanoparticles via Interfacial Agents

For polymer particles, recent studies emphasized that the particle shape—not size—plays the dominant role in novel applications in fields ranging from nanotechnology, biomedicine, to photonics, which has intensified the quest...

A continuous flow-through strategy to produce highly isotactic poly(isobutyl vinyl ether) via cationic polymerization

Tubular reactor strategy is designed for the continuous flow cationic polymerization of isobutyl vinyl ether, which gives higher isotacticity than conventional batch process and demonstrates technical advantages for potential industrial applications.

Autonomous polymer synthesis delivered by multi-objective closed-loop optimisation

Application of artificial intelligence and machine learning for polymer discovery offers an opportunity to meet the drastic need for the next generation high performing and sustainable polymer materials. Here, these...

Anionic polymerizations in a microreactor

Anionic polymerizations in a microreactor enable fast mixing, high-level control, and scale-up synthesis of polymers.

Comprehensive studies of continuous flow reversible addition–fragmentation chain transfer copolymerization and its application for photoimaging materials

Thorough studies of RAFT copolymerization in a continuous flow to gain deeper insights into kinetics, reactivity, and applicability were conducted with monomers and solvents utilizable for chemically amplified resist systems.

Fully biobased triblock copolymers generated using an unconventional oscillatory plug flow reactor

Producing block polymers in continuous flow offers significant advantages in terms of versatility, efficiency and scalability.

Machine-Learning-Guided Discovery of 19F MRI Agents Enabled by Automated Copolymer Synthesis

Modern polymer science suffers from the curse of multidimensionality. The large chemical space imposed by including combinations of monomers into a statistical copolymer overwhelms polymer synthesis and characterization technology and limits the ability to systematically study structure-property relationships. To tackle this challenge in the context of 19F magnetic resonance imaging (MRI) agents, we pursued a computer-guided materials discovery approach that combines synergistic innovations in automated flow synthesis and machine learning (ML) method development. A software-controlled, continuous polymer synthesis platform was developed to enable iterative experimental-computational cycles that resulted in the synthesis of 397 unique copolymer compositions within a six-variable compositional space. The nonintuitive design criteria identified by ML, which were accomplished by exploring <0.9% of the overall compositional space, lead to the identification of >10 copolymer compositions that outperformed state-of-the-art materials.

Design of a Combined Modular and 3D-Printed Falling Film Solution Layer Crystallizer for Intermediate Purification in Continuous Production of Pharmaceuticals

A highly scalable combined modular and 3D-printed falling film crystallization device is developed and demonstrated herein; the device uses a small, complex, printed overflow-based film distribution part that ensures formation of a well-distributed heated liquid film around a modular, tubular residence time/crystallizer section, enabling extended residence times to be achieved. A model API (ibuprofen) and impurity (ibuprofen ethyl ester) were used as a test system in the evaluation of the novel crystallizer design. The proposed crystallizer was run using three operational configurations: batch, cyclical batch, and continuous feed, all with intermittent removal of product. Results were suitable for intermediate purification requirements, and stable operation was demonstrated over multiple cycles, indicating that this approach should be compatible with parallel semicontinuous operation for intermediate purification and solvent swap applications in the manufacture of drugs.

High-Throughput Routes to Biomaterials Discovery

Many existing clinical treatments are limited in their ability to completely restore decreased or lost tissue and organ function, an unenviable situation only further exacerbated by a globally aging population. As a result, the demand for new medical interventions has increased substantially over the past 20 years, with the burgeoning fields of gene therapy, tissue engineering, and regenerative medicine showing promise to offer solutions for full repair or replacement of damaged or aging tissues. Success in these fields, however, inherently relies on biomaterials that are engendered with the ability to provide the necessary biological cues mimicking native extracellular matrixes that support cell fate. Accelerating the development of such "directive" biomaterials requires a shift in current design practices toward those that enable rapid synthesis and characterization of polymeric materials and the coupling of these processes with techniques that enable similarly rapid quantification and optimization of the interactions between these new material systems and target cells and tissues. This manuscript reviews recent advances in combinatorial and high-throughput (HT) technologies applied to polymeric biomaterial synthesis, fabrication, and chemical, physical, and biological screening with targeted end-point applications in the fields of gene therapy, tissue engineering, and regenerative medicine. Limitations of, and future opportunities for, the further application of these research tools and methodologies are also discussed.

CFD analysis of asymmetric mixing at different inlet configurations of a split-and-recombine micro mixer

In the scope of the ENPRO II initiative (Energy Efficiency and Process Intensification for the Chemical Industry), a major challenge of process intensification of polymer synthesis in continuous systems is fouling. Pre-mixing is a key aspect to prevent fouling and is achieved through milli and micro structured devices (Bayer et al. 1). While equal volume flow ratios are well investigated in milli and micro systems, asymmetric mixing tasks have received less attention. This paper investigates the dependency of mixing phenomena on different flow rate ratios and modified inlet geometries. A split-and-recombine (SAR) mixer is modified by means of an injection capillary to facilitate the asymmetric mixing task. Asymmetric volume flows of ratios between 1:15 and 1:60 are investigated; the velocity ratios range from 0.5 to 2. The setup is simulated with the Computational Fluid Dynamics (CFD) tool ANSYS®;Fluent. The species equation is solved directly without the use of micro mixing models. The simulation is validated by means of a concentration field in a mixing Tee using Laser-Induced Fluorescence (LIF) with a Confocal Laser Scanning Microscope (CLSM). The three dimensional flow structures and the mixing quality are analyzed as a measure for micro mixing. The calculated concentration fields show good agreement with the experimental results and reveal the secondary flow structures and chaotic advection within the channel. The injection of the small feed stream is found to be very efficient when drawn into the secondary structures, increasing the potential of diffusive mixing. CFD simulations help to understand and locate such structures and improve the mixing performance.

Manganese-Catalyzed Batch and Continuous Flow Cationic RAFT Polymerization Induced by Visible Light

We present a robust manganese-catalyzed cationic reversible addition-fragmentation chain transfer (RAFT) polymerization induced by visible light. Well-defined poly(vinyl ether)s with controlled molecular weight and molecular weight distributions (MWDs) can be conveniently prepared at room temperature without monomer purification. The commercially available manganese carbonyl bromide is used as the photocatalyst for cationic RAFT polymerization. Moreover, this method has been further applied in both batch and continuous flow systems, providing a visible light induced flow cationic polymerization under mild conditions.

Prospects of Using Biocatalysis for the Synthesis and Modification of Polymers

Trends in the dynamically developing application of biocatalysis for the synthesis and modification of polymers over the past 5 years are considered, with an emphasis on the production of biodegradable, biocompatible and functional polymeric materials oriented to medical applications. The possibilities of using enzymes not only as catalysts for polymerization but also for the preparation of monomers for polymerization or oligomers for block copolymerization are considered. Special attention is paid to the prospects and existing limitations of biocatalytic production of new synthetic biopolymers based on natural compounds and monomers from biomass, which can lead to a huge variety of functional biomaterials. The existing experience and perspectives for the integration of bio- and chemocatalysis in this area are discussed.