Stereochemistry-Controlled Mechanical Properties and Degradation in 3D-Printable Photosets

Effect of active carbonyl-carboxyl ratio on dynamic Schiff base crosslinking and its modulation of high-performance oxidized starch-chitosan hydrogel by hot extrusion 3D printing

The quest to develop 3D starch-based printing hydrogels for the controlled release of active substances with excellent mechanical and printing properties has gained significant attention. This work introduced a facile method based on crosslinking via Schiff base reaction for preparing bicomponent hydrogels. The method involved the utilization of customizable oxidized starch (OS) and chitosan (CS), enabling superior printing performance through the precise control of various active carbonyl-carboxyl ratios (ACR, 2:1, 1:1, and 2:3, respectively) of OS. OS-CS hydrogel (OSC) with an ACR level of 2:1 (OS-2-y%CS) underwent rearrangement during printing environment, fostering increased Schiff base reaction with a higher crosslinking degree and robust high structural recovery (>95 %). However, with decreasing ACR levels (from 2:1 to 2:3), the printing performance and mechanical strength of printed OSC (POSC) declined due to lower Schiff base bonds and increased phase separation. Compared with printed OS, POS-2-2%CS exhibited a remarkable 1250.52 % increase in tensile strength and a substantial 2424.71 % boost in compressive strength, enhanced shape fidelity and notable self-healing properties. Moreover, POS-2-2%CS exhibited stable diffusive drug release, showing potential application in the pH-responsive release of active substances. Overall, controlling the active carbonyl-carboxyl ratios provided an efficient and manageable approach for preparing high-performance 3D-printed hydrogels.

Controlled Transdermal Delivery of Dexamethasone for Pain Management via Photochemically 3D-Printed Bioresorbable Microneedle Arrays

Microneedle array patches (MAPs) are extensively studied for transdermal drug delivery. Additive manufacturing enables precise control over MAP customization and rapid fabrication. However, the scope of 3D-printable, bioresorbable materials is limited. Dexamethasone (DXM) is widely used to manage inflammation and pain, but its application is limited by systemic side effects. Thus, it is crucial to achieve high local drug concentrations while maintaining low serum levels. Here, poly(propylene fumarate-co-propylene succinate) oligomers are fabricated into DXM-loaded, bioresorbable MAPs via continuous liquid interface production 3D printing. Thiol-ene click chemistry yields MAPs with tailorable mechanical and degradation properties. DXM-loaded MAPs exhibit controlled elution of drug in vitro. Transdermal application of DXM-loaded MAPs in a murine tibial fracture model leads to substantial relief of postoperative pain. Pharmacokinetic analysis shows that MAP administration is able to control pain at a significantly lower dose than intravenous administration. This work expands the material properties of 3D-printed poly(propylene fumarate-co-propylene succinate) copolyesters and their use in drug delivery applications.

cis-Selective Acyclic Diene Metathesis Polymerization of ,-Dienes

The cis/trans stereochemistry of repeating alkenes in polymers provides a powerful handle to modulate the thermal and mechanical properties of these soft materials, but synthetic methods to precisely dictate this parameter remain scarce. We report herein a cis-selective acyclic diene metathesis (ADMET) polymerization of readily available α,ω-diene monomers with high functional group tolerance. Identification of a highly stereoselective cyclometalated Ru catalyst allowed the synthesis of a broad array of polymers with cis contents up to 99%. This platform was leveraged to study the impact of the cis geometry on the thermal and mechanical properties of polyalkenamers, including an ABA triblock copolymer synthesized via extension of a cis-rich telechelic polyoctenamer with d,l-lactide. These results suggest that cis-selective ADMET affords an efficient strategy to tune the properties of a variety of polymers.

Design of Microstructure-Engineered Polymers for Energy and Environmental Conservation

With the ever-growing demand for sustainability, designing polymeric materials using readily accessible feedstocks provides potential solutions to address the challenges in energy and environmental conservation. Complementing the prevailing strategy of varying chemical composition, engineering microstructures of polymer chains by precisely controlling their chain length distribution, main chain regio-/stereoregularity, monomer or segment sequence, and architecture creates a powerful toolbox to rapidly access diversified material properties. In this Perspective, we lay out recent advances in utilizing appropriately designed polymers in a wide range of applications such as plastic recycling, water purification, and solar energy storage and conversion. With decoupled structural parameters, these studies have established various microstructure-function relationships. Given the progress outlined here, we envision that the microstructure-engineering strategy will accelerate the design and optimization of polymeric materials to meet sustainability criteria.

Closed-loop recyclable and biodegradable thioester-based covalent adaptable networks

Closed-loop recyclable and biodegradable aliphatic covalent adaptable networks (CANs) based on dynamic β-CO thioester linkages that exhibit a service temperature beyond 100 °C are reported. These CANs possessing tensile strength and modulus values of up to 0.3 and 3 MPa, respectively, effectively undergo stress relaxation above 100 °C. The samples exhibit creep resistance ability and low hysteresis loss, and are repeatedly reprocessable at 120 °C. These CANs are depolymerizable to monomers under mild conditions and lose notable mechanical strength (92.4%) and weight (76.5%) within ∼35 days under natural biodegradation conditions.

Vat Photopolymerization Additive Manufacturing of Tough, Fully Recyclable Thermosets

To advance the capabilities of additive manufacturing, novel resin formulations are needed that produce high-fidelity parts with desired mechanical properties that are also amenable to recycling. In this work, a thiol-ene-based system incorporating semicrystallinity and dynamic thioester bonds within polymer networks is presented. It is shown that these materials have ultimate toughness values >16 MJ cm^-3, comparable to high-performance literature precedents. Significantly, the treatment of these networks with excess thiols facilitates thiol-thioester exchange that degrades polymerized networks into functional oligomers. These oligomers are shown to be amenable to repolymerization into constructs with varying thermomechanical properties, including elastomeric networks that recover their shape fully from >100% strain. Using a commercial stereolithographic printer, these resin formulations are printed into functional objects including both stiff (E ∼ 10-100 MPa) and soft (E ∼ 1-10 MPa) lattice structures. Finally, it is shown that the incorporation of both dynamic chemistry and crystallinity further enables advancement in the properties and characteristics of printed parts, including attributes such as self-healing and shape-memory.

Anti-adhesive bioresorbable elastomer-coated composite hernia mesh that reduce intraperitoneal adhesions

Intraperitoneal adhesions (IAs) are a major complication arising from abdominal repair surgeries, including hernia repair procedures. Herein, we fabricated a composite mesh device using a macroporous monofilament polypropylene mesh and a degradable elastomer coating designed to meet the requirements of this clinical application. The degradable elastomer was synthesized using an organo-base catalyzed thiol-yne addition polymerization that affords independent control of degradation rate and mechanical properties. The elastomeric coating was further enhanced by the covalent tethering of antifouling zwitterion molecules. Mechanical testing demonstrated the elastomer forms a robust coating on the polypropylene mesh does not exhibit micro-fractures, cracks or mechanical delamination under cyclic fatigue testing that exceeds peak abdominal loads (50 N/cm). Quartz crystal microbalance measurements showed the zwitterionic functionalized elastomer further reduced fibrinogen adsorption by 73% in vitro when compared to unfunctionalized elastomer controls. The elastomer exhibited degradation with limited tissue response in a 10-week murine subcutaneous implantation model. We also evaluated the composite mesh in an 84-day study in a rabbit cecal abrasion hernia adhesion model. The zwitterionic composite mesh significantly reduced the extent and tenacity of IAs by 94% and 90% respectively with respect to uncoated polypropylene mesh. The resulting composite mesh device is an excellent candidate to reduce complications related to abdominal repair through suppressed fouling and adhesion formation, reduced tissue inflammation, and appropriate degradation rate.

3D-Printed Microarray Patches for Transdermal Applications

The intradermal (ID) space has been actively explored as a means for drug delivery and diagnostics that is minimally invasive. Microneedles or microneedle patches or microarray patches (MAPs) are comprised of a series of micrometer-sized projections that can painlessly puncture the skin and access the epidermal/dermal layer. MAPs have failed to reach their full potential because many of these platforms rely on dated lithographic manufacturing processes or molding processes that are not easily scalable and hinder innovative designs of MAP geometries that can be achieved. The DeSimone Laboratory has recently developed a high-resolution continuous liquid interface production (CLIP) 3D printing technology. This 3D printer uses light and oxygen to enable a continuous, noncontact polymerization dead zone at the build surface, allowing for rapid production of MAPs with precise and tunable geometries. Using this tool, we are now able to produce new classes of lattice MAPs (L-MAPs) and dynamic MAPs (D-MAPs) that can deliver both solid state and liquid cargos and are also capable of sampling interstitial fluid. Herein, we will explore how additive manufacturing can revolutionize MAP development and open new doors for minimally invasive drug delivery and diagnostic platforms.

Click Step-Growth Polymerization and E/Z Stereochemistry Using Nucleophilic Thiol-yne/-ene Reactions: Applying Old Concepts for Practical Sustainable (Bio)Materials

Polymer sustainability is synonymous with "bioderived polymers" and the zeitgeist of "using renewable feedstocks". However, this sentiment does not adequately encompass the requirements of sustainability in polymers. In addition to recycling considerations and mechanical performance, following green chemistry principles also needs to be maximized to improve the sustainability of polymer synthesis. The synthetic cost (i.e., maximizing atom economy, reducing chemical hazards, and lowering energy requirements) of producing polymers should be viewed as equally important to the monomer source (biomass vs petrol platform chemicals). Therefore, combining the use of renewable feedstocks with efficient syntheses and green chemistry principles is imperative to delivering truly sustainable polymers. The high efficiency, atom economy, and single reaction trajectories that define click chemistry reactions position them as ideal chemical approaches to synthesize polymers in a sustainable manner while simultaneously expanding the structural scope of accessible polymers from sustainably sourced chemicals.Click step-growth polymerization using the thiol-yne Michael addition, a reaction first reported over a century ago, has emerged as an extremely mild and atom-efficient pathway to yield high-performance polymers with controllable E/Z stereochemistry along the polymer backbone. Building on studies of aromatic thiol-yne polymers, around 10 years ago our group began investigating the thiol-yne reaction for the stereocontrolled synthesis of alkene-containing aliphatic polyesters. Our early studies established a convenient path to high-molecular-weight (>100 kDa) E-rich or Z-rich step-growth polymers by judiciously changing the catalyst and/or reaction solvent. This method has since been adapted to synthesize fast-degrading polyesters, high-performance polyamides, and resilient hydrogel biomaterials. Across several systems, we have observed dramatic differences in material properties among polymers with different alkene stereochemistry.We have also explored the analogous thiol-ene Michael reaction to create high-performance poly(ester-urethanes) with precise E/Z stereochemistry. In contrast to the stereoselective thiol-yne polymerization, here the use of monomers with predefined E/Z (geometric) isomerism (arising from either alkenes or the planar rigidity of ring units) affords polymers with total control over stereochemistry. This advancement has enabled the synthesis of tough, degradable materials that are derived from sustainable monomer feedstocks. Employing isomers of sugar-derived isohexides, bicyclic rigid-rings possessing geometric isomerism, led to degradable polymers with fundamentally opposing mechanical behavior (i.e., plastic vs elastic) simply by adjusting the stereochemistry of the isohexide.In this Account, we feature our investigation of thiol-yne/-ene click step-growth polymers and efforts to establish structure-property relationships toward degradable materials with practical mechanical performance in the context of sustainable polymers and/or biomaterials. We have paid attention to installing and controlling geometric isomerism by using these click reactions, an overarching objective of our work in this research area. The exquisite control of geometric isomerism that is possible within polymer backbones, as enabled by convenient click chemistry reactions, showcases a powerful approach to creating multipurpose degradable polymers.

Sugar-Based Polymers with Stereochemistry-Dependent Degradability and Mechanical Properties

Stereochemistry in polymers can be used as an effective tool to control the mechanical and physical properties of the resulting materials. Typically, though, in synthetic polymers, differences among polymer stereoisomers leads to incremental property variation, i.e., no changes to the baseline plastic or elastic behavior. Here we show that stereochemical differences in sugar-based monomers yield a family of nonsegmented, alternating polyurethanes that can be either strong amorphous thermoplastic elastomers with properties that exceed most cross-linked rubbers or robust, semicrystalline thermoplastics with properties comparable to commercial plastics. The stereochemical differences in the monomers direct distinct intra- and interchain supramolecular hydrogen-bonding interactions in the bulk materials to define their behavior. The chemical similarity among these isohexide-based polymers enables both statistical copolymerization and blending, which each afford independent control over degradability and mechanical properties. The modular molecular design of the polymers provides an opportunity to create a family of materials with divergent properties that possess inherently built degradability and outstanding mechanical performance.

The Mechanics of Forming Ideal Polymer-Solvent Combinations for Open-Loop Chemical Recycling of Solvents and Plastics

The inherent value and use of hydrocarbons from waste plastics and solvents can be extended through open-loop chemical recycling, as this process converts plastic to a range of non-plastic materials. This process is enhanced by first creating plastic-solvent combinations from multiple sources, which then are streamlined through a single process stream. We report on the relevant mechanics for streamlining industrially relevant polymers such as polystyrene (PS), polypropylene (PP), high-density polyethylene (HDPE), and acrylonitrile butadiene styrene (ABS) into chemical slurries mixed with various organic solvents such as toluene, xylene, and cyclohexane. The miscibility of the polymer feedstock within the solvent was evaluated using the Relative Energy Difference method, and the dissolution process was evaluated using the "Molecular theories in a continuum framework" model. These models were used to design a batch process yielding 1 tonne/h slurry by setting appropriate assumptions including constant viscosity of solvents, disentanglement-controlled dissolution mechanism, and linear increase in the dissolved polymer's mass fraction over time. Solvent selection was found to be the most critical parameter for the dissolution process. The characteristics of the ideal solvent are high affinity to the desired polymer and low viscosity. This work serves as a universal technical guideline for the open-loop chemical recycling of plastics, avoiding the growth of waste plastic by utilising them as a carbon feedstock towards a circular economy framework.