Photoinitiator Selection and Concentration in Photopolymer Formulations towards Large-Format Additive Manufacturing

Photopolymers are an attractive option for large-format additive manufacturing (LFAM), because they can be formulated from structural thermosets and cure rapidly in ambient conditions under low-energy ultraviolet light-emitting diode (UV LED) lamps. Photopolymer cure is strongly influenced by the depth penetration of UV light, which can be limited in the 2–4 mm layer thicknesses typical of LFAM. Photoinitiator (PI) systems that exhibit photobleaching have proven useful in thick-section cure applications, because they generate a photoinitiation wavefront, but this effect is time-dependent. This study investigates the light transmission and through-thickness cure behavior in (meth)acrylate photopolymer formulations with the photobleaching initiator bis(2,4,6-trimethylbenzoyl)-phenylphosphine oxide (BAPO). Utilizing an optical model developed by Kenning et al., lower concentrations (0.1 wt% to 0.5 wt%) of BAPO were predicted to yield rapid onset of photoinitiation. In situ cure measurements under continuous UV LED irradiation of 380 mW/cm² showed that a 0.1 wt% concentration of BAPO achieved peak polymerization rate within 2.5 s at a 3-mm depth. With only 1 s of irradiation at 1.7 W/cm² intensity, the 0.1 wt% BAPO formulation also achieved the highest level of cure of the formulas tested. For an irradiation dose of 5.5 J/cm² at a duration of 3.7 s, cured polymer specimens achieved a flexural strength of 108 MPa and a flexural modulus of 3.1 GPa. This study demonstrates the utility of optical modeling as a potential screening tool for new photopolymer formulations, primarily in identifying an upper limit to PI concentration for the desired cure depth. The results also show that photobleaching provides only a limited benefit for LFAM applications with short (1.0 s to 3.7 s) UV irradiation times and indicate that excess PI concentration can inhibit light transmission even under extended irradiation times up to 60 s.

Radical photoinitiation with LEDs and applications in the 3D printing of composites

Radical initiation upon LED light irradiation is discussed herein as well as its application in additive manufacturing. The ability of manufacturing complex structures, freedom of design, low energy consumption, fast prototyping, and excellent spatial resolution are the main benefits of the 3D printing technology by photopolymerization. Therefore, the 3D printing of composites through photopolymerization processes is developing rapidly in the academia and industry, and has been a turning point of additive manufacturing (AM). In the present review, an overview of radical initiation with LEDs (i.e., the photopolymerization LED technology, the photoinitiating systems, and the polymerizable media) and of the main 3D printing methods by photopolymerization, materials, and their applications in different fields has been carried out. As a challenging topic, the issue of light penetration in a filled matrix for the access to composites is discussed, including the light transmittance of the composite, the mismatch of the refractive index between the filler and the monomer, the factors of the filler, and the adverse influence of low light penetration on the 3D printing process. In particular, the popular applications of 3D printing by photopolymerization in biomedical science, electronic industry, materials for adsorption, and 4D printing are discussed. Overall, this review gives an overview of the 3D printing of polymer matrix composites through photopolymerization processes as a benchmark for future research and development.

Synthesis and testing of ZnO nanoparticles for photo-initiation: experimental observation of two different non-migration initiators for bulk polymerization

The migration and transport of polymerization initiators are problematic for commercially used polymerization procedures. For example, UV printing of packaging generates products with potentially harmful components that come in contact with food. Enlarging the size of the initiator is the only way to prevent contamination, e.g., by gas phase transport. In this manuscript, the synthesis and advanced and full analyses of novel nanoparticle-based types of non-migration, fragmenting and non-fragmenting photo-initiators will be presented in detail. This study introduces non-fragmenting/"Norrish type II" and fragmenting/"Norrish type I" ZnO nanoparticle-based initiators and compares them with two commercial products, a "Norrish type I" initiator and a "Norrish type II" initiator. Therefore, inter alia, the recently developed analysis involves examining the solidification by UV-vis and the double bond content by Raman. Irradiation is performed using absolute and spectrally calibrated xenon flash lights. A novel procedure for absolute and spectral calibration of such light sources is also presented. The non-optimized "Norrish type II" particle-based initiator is already many times faster than benzophenone, which is a molecular initiator of the same non-fragmenting type. This experimentally observed difference in reactive particle-based systems without co-initiators is unexpected. Co-initiators are normally an additional molecular species, which leads to migration problems. The discovery of significant initiation potential resulting in a very well-dispersed organic-inorganic hybrid material suggests a new field of research opportunities at the interface of physical chemistry, polymer chemistry and engineering science, with enormous value for human health.

Method to analyse energy and intensity dependent photo-curing of acrylic esters in bulk

The photo-polymerizations induced by three different model resins, containing well-known commercial initiators, are monitored by an in situ Raman UV-vis system and analysed in detail.