Efficient 3D printing via photooxidation of ketocoumarin based photopolymerization

Novel Photocatalyst Based on Through-Space Charge Transfer Induced Intersystem Crossing Enables Rapid and Efficient Polymerization Under Low-Power Excitation Light

Currently, most photoredox catalysis polymerization systems are limited by high excitation power, long polymerization time, or the requirement of electron donors due to the precise design of efficient photocatalysts still poses a great challenge. Herein, we propose a new approach: the creation of efficient photocatalysts having low ground state oxidation potentials and high excited state energy levels, along with through-space charge transfer (TSCT) induced intersystem crossing (ISC) properties. A cabazole-naphthalimide (NI) dyad (NI-1) characterized by long triplet excited state lifetime (τT=62 μs), satisfactory ISC efficiency (ΦΔ=54.3 %) and powerful reduction capacity [Singlet: E1/2 (PC+1/*PC)=-1.93 eV, Triplet: E1/2 (PC+1/*PC)=-0.84 eV] was obtained. An efficient and rapid polymerization (83 % conversion of 1 mM monomer in 30 s) was observed under the conditions of without electron donor, low excitation power (10 mW cm-2) and low catalyst (NI-1) loading (<50 μM). In contrast, the conversion rate was lower at 29 % when the reference catalyst (NI-4) was used for photopolymerization under the same conditions, demonstrating the advantage of the TSCT photocatalyst. Finally, the TSCT material was used as a photocatalyst in practical lithography for the first time, achieving pattern resolutions of up to 10 μm.

New Application of Multiresonance Organic Delayed Fluorescence Dyes: High-Performance Photoinitiating Systems for Acrylate and Epoxy Photopolymerization and Photoluminescent Pattern Preparation

The primary focus of photopolymerization research is to advance highly efficient visible photoinitiating systems (PISs) as alternatives to conventional ultraviolet (UV) photoinitiators. We developed four multiresonance emitters (BIC-pCz, BNO1, BO-DICz, and TPABO-DICz) to sensitize iodonium salt (Iod) and initiate free-radical and cationic photopolymerization under visible light for the first time. The TPABO-DICz/Iod system achieved a double-bond conversion of over 70% within just 4 s of exposure to green light (520 nm), while the BNO1/Iod system achieved a double-bond conversion exceeding 50% with 10 s of exposure to red light (630 nm). The photochemical properties were studied through thermodynamic research, steady-state photolysis, and electron spin resonance. Photolithography techniques were employed to fabricate photoluminescent films and micrometer-scale patterns utilizing the blue-emitting BIC-pCz dye, showcasing the potential of photolithography in the production of photoluminescent pixels. Additionally, the BIC-pCz/Iod and TPABO-DICz/Iod systems have been employed to rapidly fabricate photoluminescent polymer patterns using a digital-light-processing 3D printer with a low-intensity light (3.2 mW cm-2). These multiresonance emitters show exceptional photosensitizing effects and can act as fluorescent dyes in photoluminescent patterns, highlighting the potential of utilizing photopolymerization for OLED applications.

Soft Actuators and Actuation: Design, Synthesis, and Applications

Soft actuators are one of the most promising technological advancements with potential solutions to diverse fields' day-to-day challenges. Soft actuators derived from hydrogel materials possess unique features such as flexibility, responsiveness to stimuli, and intricate deformations, making them ideal for soft robotics, artificial muscles, and biomedical applications. This review provides an overview of material composition and design techniques for hydrogel actuators, exploring 3D printing, photopolymerization, cross-linking, and microfabrication methods for improved actuation. It examines applications of hydrogel actuators in biomedical, soft robotics, bioinspired systems, microfluidics, lab-on-a-chip devices, and environmental, and energy systems. Finally, it discusses challenges, opportunities, advancements, and regulatory aspects related to hydrogel actuators.

Rapid Continuous 3D Printing via Orthogonal Dual-Color Photoinitiation and Photoinhibition

Stereolithographic additive manufacturing technology has developed from point-by-point scanning exposure to layer-by-layer masking curing and even volumetric printing. Rapid prototyping is one of the important goals pursued by researchers. A continuous three-dimensional (3D) printing system based on the dual-color photoinitiation and photoinhibition is proposed with the aim of further improving printing speed. The process of continuous 3D printing is realized through the anti-polymerization layer between the cured part and the window generated by the ultraviolet (UV) light sheet (355 nm), and dynamic masking with the blue light (470 nm). The volume of the anti-polymerization layer can be adjusted by the intensity ratio of the incident lights (IUV, 0/Iblue,0) and the size of UV laser spot to enhance the reflow filling rate of the liquid resin. For the orthogonal Gaussian anti-polymerization layer, an intensity ratio of 28.6 allows for an inhibition volume of 97.1% of the desired rectangular anti-polymerization zone with a height of 1 mm. The simulation analysis of continuous 3D printing process by flow-structure interaction reveals that the increase of the thickness of the anti-polymerization layer effectively improves the filling rate of the resin and the cross-sectional area of printing, and reduces the stress of the cured part. The experiments with two different 3D structures printing demonstrate that the filling rate and the stress have virtually no effect on the printing process at a large-scale thickness of the anti-polymerization layer, and the printing speed is capable of reaching 200 μm/s. Certainly, the printing volume and complexity can be further improved with the improvement of the system and the optimization of the resin.

Photocuring 3D Printing of Hydrogels: Techniques, Materials, and Applications in Tissue Engineering and Flexible Devices

Photocuring 3D printing of hydrogels, with sophisticated, delicate structures and biocompatibility, attracts significant attention by researchers and possesses promising application in the fields of tissue engineering and flexible devices. After years of development, photocuring 3D printing technologies and hydrogel inks make great progress. Herein, the techniques of photocuring 3D printing of hydrogels, including direct ink writing (DIW), stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP), volumetric additive manufacturing (VAM), and two photon polymerization (TPP) are reviewed. Further, the raw materials for hydrogel inks (photocurable polymers, monomers, photoinitiators, and additives) and applications in tissue engineering and flexible devices are also reviewed. At last, the current challenges and future perspectives of photocuring 3D printing of hydrogels are discussed.

Novel High-Performance Glyoxylate Derivative-Based Photoinitiators for Free Radical Photopolymerization and 3D Printing with Visible LED

Investigations concerning the glyoxylate moiety as a photocleavable functional group for visible light photoinitiators, particularly in the initiation of free radical photopolymerization remain limited. This study introduces nine innovative carbazole-based ethyl glyoxylate derivatives (CEGs), which are synthesized and found to exhibit excellent photoinitiation abilities as monocomponent photoinitiating systems. Notably, these structures demonstrate robust absorption in the near-UV/visible range, surpassing the commercial photoinitiators. Moreover, the newly developed glyoxylate derivatives show higher acrylate function conversions compared to a benchmark photoinitiator (MBF) in free radical photopolymerization. Elucidation of the photoinitiation mechanism of CEGs is achieved through a comprehensive analysis involving the decarboxylation reaction and electron spin resonance spin trapping. Furthermore, their practical utility is confirmed during direct laser writing and 3D printing processes, enabling the successful fabrication of 3D printed objects. This study introduces pioneering concepts and effective strategies in the molecular design of novel photoinitiators, showcasing their potential for highly advantageous applications in 3D printing.

Recent Progress of the Vat Photopolymerization Technique in Tissue Engineering: A Brief Review of Mechanisms, Methods, Materials, and Applications

Vat photopolymerization (VP), including stereolithography (SLA), digital light processing (DLP), and volumetric printing, employs UV or visible light to solidify cell-laden photoactive bioresin contained within a vat in a point-by-point, layer-by-layer, or volumetric manner. VP-based bioprinting has garnered substantial attention in both academia and industry due to its unprecedented control over printing resolution and accuracy, as well as its rapid printing speed. It holds tremendous potential for the fabrication of tissue- and organ-like structures in the field of regenerative medicine. This review summarizes the recent progress of VP in the fields of tissue engineering and regenerative medicine. First, it introduces the mechanism of photopolymerization, followed by an explanation of the printing technique and commonly used biomaterials. Furthermore, the application of VP-based bioprinting in tissue engineering was discussed. Finally, the challenges facing VP-based bioprinting are discussed, and the future trends in VP-based bioprinting are projected.

Photoinhibiting via simultaneous photoabsorption and free-radical reaction for high-fidelity light-based bioprinting

Light-based 3D bioprinting is now employed widely to fabricate geometrically complex constructs for various biomedical applications. However, the inherent light scattering defect creates significant challenges in patterning dilute hydrogels to form high-fidelity structures with fine-scale features. Herein, we introduce a photoinhibiting approach that can effectively suppress the light scattering effect via a mechanism of simultaneous photoabsorption and free-radical reaction. This biocompatible approach significantly improves the printing resolution (~1.2 - ~2.1 pixels depending on swelling) and shape fidelity (geometric error less than 5%), while minimising the costly trial-and-error procedures. The capability in patterning 3D complex constructs using different hydrogels is demonstrated by manufacturing various scaffolds featuring intricate multi-sized channels and thin-walled networks. Importantly, cellularised gyroid scaffolds (HepG2) are fabricated successfully, exhibiting high cell proliferation and functionality. The strategy established in this study promotes the printability and operability of light-based 3D bioprinting systems, allowing numerous new applications for tissue engineering.

High-Performance Photoinitiating Systems for LED-Induced Photopolymerization

Currently, increasing attention has been focused on light-emitting diodes (LEDs)-induced photopolymerization. The common LEDs (e.g., LED at 365 nm and LED at 405 nm) possess narrow emission bands. Due to their light absorption properties, most commercial photoinitiators are sensitive to UV light and cannot be optimally activated under visible LED irradiation. Although many photoinitiators have been designed for LED-induced free radical polymerization and cationic polymerization, there is still the issue of the mating between photoinitiators and LEDs. Therefore, the development of novel photoinitiators, which could be applied under LED irradiation, is significant. Many photoinitiating systems have been reported in the past decade. In this review, some recently developed photoinitiators used in LED-induced photopolymerization, mainly in the past 5 years, are summarized and categorized as Type Ⅰ photoinitiators, Type Ⅱ photoinitiators, and dye-based photoinitiating systems. In addition, their light absorption properties and photoinitiation efficiencies are discussed.

Naphthalene-Based Oxime Esters as Type I Photoinitiators for Free Radical Photopolymerization

In order to discuss the polymerization effect from the substituted position and methoxy group of Type I photinitiators, a series of naphthalene-based oxime esters was designed and synthesized. Compared to the 2-naphthalene-substituted compound, the UV absorption region of the 1-naphthalene-based compound was greatly improved. In addition, the methoxy substitution exhibited longer absorption characteristics than did the methoxy-free one. The photochemical reaction behavior of these novel compounds was also studied by photolysis, cyclic voltammetry (CV), and electron spin resonance (ESR) experiments. Finally, the initiation abilities of naphthalene-based oxime esters toward trimethylolpropane triacrylate (TMPTA) monomer were conducted through the photo-DSC instrument under UV and a 405@nm LED lamp. Remarkedly, the naphthalene-based oxime ester (NA-3) that contains 1-naphthalene with o-methoxy substituent showed the rather red-shifted absorption region with the highest final conversion efficiency under UV (46%) and 405@nm LED (41%) lamp irradiation.

Modulating the intersystem crossing mechanism of anthracene carboxyimide-based photosensitizers via structural adjustments and application as a potent photodynamic therapeutic reagent

Herein, a series of compact anthracene carboxyimide (ACI) based donor-acceptor dyads were prepared by substituting bulky aryl moieties with various electron-donating ability to study the triplet-excited state properties. The ISC mechanism and triplet yield of the dyads were successfully tuned via structural manipulation. Efficient ISC (Φ_Δ ≈ 99%) and long-lived triplet state (τ_T ≈ 122 μs) was observed for the orthogonal anthracene-labeled ACI derivative compared to the Ph-ACI and NP-ACI dyads, which showed fast triplet state decay (τ_T ≈ 7.7 μs). Femtosecond transient absorption study demonstrated the ultrafast charge separation (CS) and efficient charge recombination (CR) in the orthogonal dyads and ISC occurring via spin-orbit charge transfer (SOCT) mechanism (AN-ACI: τ_CS = 355 fs, τ_CR = 2.41 ns; PY-ACI: τ_CS = 321 fs, τ_CR = 1.61 ns), while in Ph-ACI and NP-ACI dyads triplet populate following the normal ISC channel (nπ* → ππ* transition), no CS was observed. We found that the attachment of suitable aryl donor moiety (AN- or PY-) to the ACI core can ensure the insertion of the intermediate triplet state, resulting in a small energy gap among charge separated state (CSS) and triplet state, which leads to efficient ISC in these derivatives. The SOCT-ISC-based AN-ACI dyad was confirmed to be a potent photodynamic therapeutic reagent; an ultra-low IC₅₀ value (0.27 nM) that was nearly 214 times lower than that of the commercial Rose Bengal photosensitizer (57.8 nM) was observed.

Fabrication And In Vitro Evaluation Of 3D Printed Porous Silicate Substituted Calcium Phosphate Scaffolds For Bone Tissue Engineering

Silicate-substituted calcium phosphate (Si-CaP) ceramics, alternative materials for autogenous bone grafting, exhibit excellent osteoinductivity, osteoconductivity, biocompatibility and biodegradability; thus, they have been widely used for treating bone defects. However, the limited control over the spatial structure and weak mechanical properties of conventional Si-CaP ceramics hinder their wide application. Here, we used digital light processing (DLP) printing technology to fabricate a novel porous 3D printed Si-CaP scaffold to enhance the scaffold properties. Scanning electron microscopy, compression tests, and computational fluid dynamics simulations of the 3D printed Si-CaP scaffolds revealed a uniform spatial structure, appropriate mechanical properties, and effective interior permeability. Furthermore, compared to Si-CaP groups, 3D printed Si-CaP groups exhibited sustained release of silicon (Si), calcium (Ca) and phosphorus (P) ions. Furthermore, 3D printed Si-CaP groups had more comprehensive and persistent osteogenic effects due to increased osteogenic factor expression and calcium deposition. Our results show that the 3D printed Si-CaP scaffold successfully improved bone marrow mesenchymal stem cell (BMSCs) adhesion, proliferation and osteogenic differentiation and possessed a distinct apatite mineralization ability. Overall, with the help of DLP printing technology, Si-CaP ceramic materials facilitate the fabrication of ideal bone tissue engineering scaffolds with essential elements, providing a promising approach for bone regeneration. This article is protected by copyright. All rights reserved.

Digital Light Processing 3D Printing of Tough Supramolecular Hydrogels with Sophisticated Architectures as Impact-Absorption Elements

Processing tough hydrogels into sophisticated architectures is crucial for their applications as structural elements. However, Digital Light Processing (DLP) printing of tough hydrogels is challenging because of the low-speed gelation and toughening process. Described here is a simple yet versatile system suitable for DLP printing to form tough hydrogel architectures. The aqueous precursor consists of commercial photoinitiator, acrylic acid, and zirconium ion (Zr⁴⁺ ), readily forming tough metallo-supramolecular hydrogel under digital light because of in situ formation of carboxyl-Zr⁴⁺ coordination complexes. The high-stiffness and antiswelling properties of as-printed gel enable high-efficiency printing to form high-fidelity constructs. Furthermore, swelling-induced morphing of the gel is also achieved by encoding structure gradients during the printing with grayscale digital light. Mechanical properties of the printed hydrogels are further improved after incubation in water due to the variation of local pH and rearrangement of coordination complex. The swelling-enhanced stiffness affords the printed hydrogel with shape fixation ability after manual deformations, and thereby provides an additional avenue to form more complex configurations. These printed hydrogels are used to devise an impact-absorption element or a high-sensitivity pressure sensor as proof-of-concept examples. This work should merit engineering of other tough gels and extend their scope of applications in diverse fields.

Spongy all-in-liquid materials by in-situ formation of emulsions at oil-water interfaces

Printing a structured network of functionalized droplets in a liquid medium enables engineering collectives of living cells for functional purposes and promises enormous applications in processes ranging from energy storage to tissue engineering. Current approaches are limited to drop-by-drop printing or face limitations in reproducing the sophisticated internal features of a structured material and its interactions with the surrounding media. Here, we report a simple approach for creating stable liquid filaments of silica nanoparticle dispersions and use them as inks to print all-in-liquid materials that consist of a network of droplets. Silica nanoparticles stabilize liquid filaments at Weber numbers two orders of magnitude smaller than previously reported in liquid-liquid systems by rapidly producing a concentrated emulsion zone at the oil-water interface. We experimentally demonstrate the printed aqueous phase is emulsified in-situ; consequently, a 3D structure is achieved with flexible walls consisting of layered emulsions. The tube-like printed features have a spongy texture resembling miniaturized versions of “tube sponges” found in the oceans. A scaling analysis based on the interplay between hydrodynamics and emulsification kinetics reveals that filaments are formed when emulsions are generated and remain at the interface during the printing period. Stabilized filaments are utilized for printing liquid-based fluidic channels.

All-in-liquid printing promises applications from energy storage to drug delivery and tissue engineering. Here, authors present the in-situ generation of layered emulsion in a fraction of a second at the oil-water interface forming 3D tube-like structures in a liquid medium.

Liquid Metal Nanoparticles as a Highly Efficient Photoinitiator to Develop Multifunctional Hydrogel Composites

Liquid metal (LM) composites are a class of emerging soft multifunctional materials that are promising for a variety of applications, yet the chemistry properties of LM have not been fully understood. Here, we report that LM nanoparticles can directly perform as a photoinitiator for radical polymerization and the in situ development of highly tough and multifunctional LM hydrogel composites. It is revealed that the photocatalytic activity of LM nanoparticles originates from the oxide layer on LM. Significantly, positively charged metal-organic framework (MOF) nanoparticles are used to stabilize LM nanoparticles in aqueous solutions, where the MOF can anchor on the surface of LM nanoparticles by electrostatic interaction while helping to preserve the unshielded oxide layer, therefore realizing the highly efficient photoinitiation and polymerization. The LM nanoparticle-initiated photopolymerization is shown to develop hydrogel composites featuring excellent stretchability, stimuli responsiveness, and sustained photocatalytic activity. The photocatalytic polymerization initiated by LM nanoparticles not only deepens the understanding on the semiconductor properties of the oxide skin on LM but also broadens the application scenarios of multifunctional LM/polymer composites in smart materials, wearable electronics, and soft robotics.

Innovative Application of Three-Dimensional-Printed Breast Model-Aided Reduction Mammaplasty

Symptomatic macromastia places a severe physical and psychological burden on patients. Reduction mammaplasty is the primary treatment; however, conventional surgery may lead to postoperative nipple-areolar complex necrosis due to damage to the dominant supplying arteries. In this study, we designed and fabricated an innovative, three-dimensional-printed breast vascular model to provide surgical guidance for reduction mammaplasty. Preoperative computed tomography angiography scanning data of patients were collected. The data were then processed and reconstructed using the E3D digital medical modeling software (version 17.06); the reconstructions were then printed into a personalized model using stereolithography. The three-dimensional-printed breast vascular model was thus developed for individualized preoperative surgical design. This individualized model could be used to intuitively visualize the dominant supplying arteries’ spatial location in the breasts, thereby allowing effective surgical planning for reduction mammaplasty. The three-dimensional-printed breast vascular model can therefore provide an individualized preoperative design and patient education, avoid necrosis of the nipple-areolar complex, shorten operation duration, and ensure safe and effective surgery in patients.

Recent Trends in Advanced Photoinitiators for Vat Photopolymerization 3D Printing

3D printing has revolutionized the way of manufacturing with a huge impact on various fields, in particular biomedicine. Vat photopolymerization-based 3D printing techniques such as stereolithography (SLA) and digital light processing (DLP) attracted considerable attention owing to their superior print resolution, relatively high speed, low cost and flexibility in resin material design. As one key element of the SLA/DLP resin, photoinitiators or photoinitiating systems have experienced significant development in recent years, in parallel with the exploration of 3D printing (macro)monomers. The design of new photoinitiating systems can not only offer faster 3D printing speed and enable low-energy visible light fabrication, but also can bring new functions to the 3D printed products and even generate new printing methods in combination with advanced optics. This review evaluates recent trends in the development and application of advanced photoinitiators and photoinitiating systems for vat photopolymerization 3D printing, with a wide range of small molecules, polymers and nanoassemblies involved. Personal perspectives on the current limitations and future directions are eventually provided. This article is protected by copyright. All rights reserved.

Nanoparticle-Stabilized Emulsion Bioink for Digital Light Processing Based 3D Bioprinting of Porous Tissue Constructs

A challenge for bioprinting tissue constructs is enabling the viability and functionality of encapsulated cells. Rationally designed bioink that can create appropriate biophysical cues shows great promise for overcoming such challenges. Here, a nanoparticle-stabilized emulsion bioink for direct fabrication of porous tissue constructs by digital light processing based 3D bioprinting technology is introduced. The emulsion bioink is integrated by the mixture of aqueous dextran microdroplets and gelatin methacryloyl solution and is further rendered stable by β-lactoglobulin nanoparticles. After bioprinting, the printed tissue constructs create the macroporous structure via removal of dextran, thereby providing favorable biophysical cues to promote the viability, proliferation, and spreading of the encapsulated cells. Moreover, a trachea-shaped construct containing chondrocytes is bioprinted and implanted in vivo. The results demonstrate that the generated macroporous construct is of benefit to cartilage tissue rebuilding. This work offers an advanced bioink for the fabrication of living tissue constructs by activating the cell behaviors and functions in situ and can lead to the development of 3D bioprinting.

General One-Pot Method for Preparing Highly Water-Soluble and Biocompatible Photoinitiators for Digital Light Processing-Based 3D Printing of Hydrogels

We report a facile but general method to prepare highly water-soluble and biocompatible photoinitiators for digital light processing (DLP)-based 3D printing of high-resolution hydrogel structures. Through a simple and straightforward one-pot procedure, we can synthesize a metal-phenyl(2,4,6-trimethylbenzoyl)phosphinates (M-TMPP)-based photoinitiator with excellent water solubility (up to ∼50 g/L), which is much higher than that of previously reported water-soluble photoinitiators. The M-TMPP aqueous solutions show excellent biocompatibility, which meets the prerequisite for biomedical applications. Moreover, we used M-TMPP to prepare visible light (405 nm)-curable hydrogel precursor solutions for 3D printing hydrogel structures with a high water content (80 wt %), high resolution (∼7 μm), high deformability (more than 80% compression), and complex geometry. The printed hydrogel structures demonstrate great potential in flexible electronic sensors due to the fast mechanical response and high stability under cyclic loadings.

The NIR-sensitized cationic photopolymerization of oxetanes in combination with epoxide and acrylate monomers

NIR-sensitized photopolymerisation at 805 nm facilitates the cationic polymerization of oxetanes. This can additionally be combined with free-radical polymerization.