Photopolymerization Approach to Advanced Polymer Composites: Integration of Surface-Modified Nanofillers for Enhanced Properties

The incorporation of functionalized nanofillers into polymers via photopolymerization approach has gained significant attention in recent years due to the unique properties of the resulting composite materials. Surface modification of nanofillers plays a crucial role in their compatibility and polymerization behavior within the polymer matrix during photopolymerization. This review focuses on the recent developments in surface modification of various nanofillers, enabling their integration into polymer systems through photopolymerization. The review discusses the key aspects of surface modification of nanofillers, including the selection of suitable surface modifiers, such as photoinitiators and polymerizable groups, as well as the optimization of modification conditions to achieve desired surface properties. The influence of surface modification on the interfacial interactions between nanofillers and the polymer matrix is also explored, as it directly impacts the final properties of the nanocomposites. Furthermore, the review highlights the applications of nanocomposites prepared by photopolymerization, such as sensors, gas separation membranes, purification systems, optical devices, and biomedical materials. By providing a comprehensive overview of the surface modification strategies and their impact on the photopolymerization process and the resulting nanocomposite properties, this review aims to inspire new research directions and innovative ideas in the development of high-performance polymer nanocomposites for diverse applications.

Growing three-dimensional objects with light

Vat photopolymerization (VP) additive manufacturing enables fabrication of complex 3D objects by using light to selectively cure a liquid resin. Developed in the 1980s, this technique initially had few practical applications due to limitations in print speed and final part material properties. In the four decades since the inception of VP, the field has matured substantially due to simultaneous advances in light delivery, interface design, and materials chemistry. Today, VP materials are used in a variety of practical applications and are produced at industrial scale. In this perspective, we trace the developments that enabled this printing revolution by focusing on the enabling themes of light, interfaces, and materials. We focus on these fundamentals as they relate to continuous liquid interface production (CLIP), but provide context for the broader VP field. We identify the fundamental physics of the printing process and the key breakthroughs that have enabled faster and higher-resolution printing, as well as production of better materials. We show examples of how in situ print process monitoring methods such as optical coherence tomography can drastically improve our understanding of the print process. Finally, we highlight areas of recent development such as multimaterial printing and inorganic material printing that represent the next frontiers in VP methods.

The Influence of Thickness on the Mechanical Behaviors of 3D Printing Resins for Orthodontic Retainers

This study aimed to evaluate the mechanical behaviors of thermoformed and 3D-printed retainers with different thicknesses. Thermoformed retainers (Duran) and 3D-printed retainers (Dental LT Clear V2 and NextDent Ortho Flex) were fabricated at thicknesses of 0.5, 0.75, and 1 mm. Five samples of each material were subjected to compression, tensile, and flexural testing with the universal testing machine (Instron Ltd., Buckinghamshire, England). The results revealed that the mechanical behaviors were significantly influenced by thickness in each type of material. The increased thickness tended to increase strength and modulus in all three tests. However, Dental LT Clear V2 and Duran showed that flexural strength and modulus were inversely related to thickness. The compressive test revealed significantly greater compressive resistance in 3D-printed groups, except for the NextDent Ortho Flex at 0.5 mm. The tensile test showed that Dental LT Clear V2 at all thicknesses demonstrated significantly higher tensile strength and modulus, while NextDent Ortho Flex was significantly lowest at any thickness in tensile and flexural properties. In conclusion, the thickness significantly influenced the mechanical behaviors of the 3D-printed retainers. The 0.75 mm thickness of Dental LT Clear V2 could be considered as an alternative to fabricated retainers due to its similar mechanical properties compared with the thermoformed material.

Polymers in 3D printing of external maxillofacial prostheses and in their retention systems

Maxillofacial defects, arising from trauma, oncological disease or congenital abnormalities, detrimentally affect daily life. Prosthetic repair offers the aesthetic and functional reconstruction with the help of materials mimicking natural tissues. 3D polymer printing enables the design of patient-specific prostheses with high structural complexity, as well as rapid and low-cost fabrication on-demand. However, 3D printing for prosthetics is still in the early stage of development and faces various challenges for widespread use. This is because the most suitable polymers for maxillofacial restoration are soft materials that do not have the required printability, mechanical strength of the printed parts, as well as functionality. This review focuses on the challenges and opportunities of 3D printing techniques for production of polymer maxillofacial prostheses using computer-aided design and modeling software. Review discusses the widely used polymers, as well as their blends and composites, which meet the most important assessment criteria, such as the physicochemical, biological, aesthetic properties and processability in 3D printing. In addition, strategies for improving the polymer properties, such as their printability, mechanical strength, and their ability to print multimaterial and architectural structures are highlighted. The current state of the prosthetic retention system is presented with a focus on actively used polymer adhesives and the recently implemented prosthesis-supporting osseointegrated implants, with an emphasis on their creation from 3D-printed polymers. The successful prosthetics is discussed in terms of the specificity of polymer materials at the restoration site. The approaches and technological prospects are also explored through the examples of the nasal, auricle and ocular prostheses, ranging from prototypes to end-use products.

Soluble Fluorinated Cardo Copolyimide as an Effective Additive to Photopolymerizable Compositions Based on Di(meth)acrylates: Application for Highly Thermostable Primary Protective Coating of Silica Optical Fiber

The development of photocurable compositions is in high demand for the manufacture of functional materials for electronics, optics, medicine, energy, etc. The properties of the final photo-cured material are primarily determined by the initial mixture, which needs to be tuned for each application. In this study we propose to use simple systems based on di(meth)acrylate, polyimide and photoinitiator for the preparation of new photo-curable compositions. It was established that a fluorinated cardo copolyimide (FCPI) based on 2,2-bis-(3,4-dicarboxydiphenyl)hexafluoropropane dianhydride, 9,9-bis-(4-aminophenyl)fluorene and 2,2-bis-(4-aminophenyl)hexafluoropropane (1.00:0.75:0.25 mol) has excellent solubility in di(met)acrylates. This made it possible to prepare solutions of FCPI in such monomers, to study the effect of FCPI on the kinetics of their photopolymerization in situ and the properties of the resulting polymers. According to the obtained data, the solutions of FCPI (23 wt.%) in 1,4-butanediol diacrylate (BDDA) and FCPI (15 wt.%) in tetraethylene glycol diacrylate were tested for the formation of the primary protective coatings of the silica optical fibers. It was found that the new coating of poly(BDDA-FCPI23%) can withstand prolonged annealing at 200 °C (72 h), which is comparable or superior to the known most thermally stable photo-curable coatings. The proposed approach can be applied to obtain other functional materials.

Interfacial energy as an approach to designing amphipathic surfaces during photopolymerization curing

Photopolymerization induced phase separation (PIPS) is a platform capable of creating heterogeneous materials from initially miscible resin solutions, where both the reaction's governing thermodynamics and kinetics significantly influence the resulting phase composition and morphology. Here, PIPS is used to develop materials in a single photopolymerization step that are hydrophobic on one face and hydrophilic on the other. These two faces possess a water contact angle difference of 50°, bridged by a bulk-scale chemical gradient. The impact of the PIPS-triggering inert additive is investigated by increasing the loading of poly(methyl methacrylate) (PMMA) in an acrylonitrile/1,6-hexanediol diacrylate comonomer resin. The extent of phase separation in the sample network depends on this loading, with increasing PMMA corresponding to macroscale domains that are more chemically and mechanically distinct. A significant period between the onsets of phase separation and reaction deceleration, determined using in situ FT-IR, facilitates this enhanced phase segregation in PMMA-modified samples. Spatially directed domain formation can be further promoted using multiple interface types in the sample mold, here, glass and stainless steel. With multiple interface types, interfacial rearrangements to minimize surface energy during resin photopolymerization result in a hydrophobic face that is nitrile-rich and a hydrophilic face that is nitrile-poor (e.g., acrylate-rich). Using this strategy, patterned wettability on a single face can also be engineered. This study illustrates the capabilities of PIPS for complex surface design and in applications requiring stark differences in surface character without sharp interfaces.

Improving the Performance of Photoactive Terpene-Based Resin Formulations for Light-Based Additive Manufacturing

Photocurable liquid formulations have been a key research focus for the preparation of mechanically robust and thermally stable networks. However, the development of renewable resins to replace petroleum-based commodities presents a great challenge in the field. From this perspective, we disclose the design of photoactive resins based on terpenes and itaconic acid, both potentially naturally sourced, to prepare photosets with adjustable thermomechanical properties. Biobased perillyl itaconate (PerIt) was synthesized from renewable perillyl alcohol and itaconic anhydride via a scalable solvent-free method. Photoirradiation of PerIt in the presence of a multiarm thiol and photoinitiator led to the formation of networks over a range of compositions. Addition of nonmodified terpenes (perillyl alcohol, linalool, or limonene) as reactive diluents allowed for more facile preparation of photocured networks. Photosets within a wide range of properties were accessed, and these could be adjusted by varying diluent type and thiol stoichiometry. The resins showed rapid photocuring kinetics and the ability to form either brittle or elastic materials, with Young's modulus and strain at break ranging from 3.6 to 358 MPa and 15 to 367%, respectively, depending on the chemical composition of the resin. Glass transition temperatures (Tg) were influenced by thioether content, with temperatures ranging from 5 to 43 °C, and all photosets displayed good thermal resistance with Td,5% > 190 °C. Selected formulations containing PerIt and limonene demonstrated suitability for additive manufacturing technologies and high-resolution objects were printed via digital light processing (DLP). Overall, this work presents a simple and straightforward route to prepare renewable resins for rapid prototyping applications.

PhotoROMP: The Future Is Bright

Since the earliest investigations of olefin metathesis catalysis, light has been the choice for controlling the catalyst activity on demand. From the perspective of energy efficiency, temporal and spatial control, and selectivity, photochemistry is not only an attractive alternative to traditional thermal manufacturing techniques but also arguably a superior manifold for advanced applications like additive manufacturing (AM). In the last three decades, pioneering work in the field of ring-opening metathesis polymerization (ROMP) has broadened the scope of material properties achievable through AM, particularly using light as both an activating and deactivating stimulus. In this Perspective, we explore trends in photocontrolled ROMP systems with an emphasis on approaches to photoinduced activation and deactivation of metathesis catalysts. Recent work has yielded a myriad of commercial and synthetically accessible photosensitive catalyst systems, although comparatively little attention has been paid to achieving precise control over polymer morphology using light. Metal-free, photophysical, and living ROMP systems have also been relatively underexplored. To take fuller advantage of both the thermomechanical properties of ROMP polymers and the operational simplicity of photocontrol, clear directions for the field are to improve the reversibility of activation and deactivation strategies as well as to further develop photocontrolled approaches to tuning cross-link density and polymer tacticity.

Synthesis of Bio-Based Polyester Resins for Vat Photopolymerization 3D Printing

Driven by environmental considerations, the scientific community has directed great effort towards the synthesis of new materials derived from renewable resources. However, for photocurable resins, most commercially available building blocks still rely on petroleum-based precursors. Herein, we present a simple synthesis route for bio-based acrylate-modified polyester resins, whose viscosity is sufficiently low for processing them with vat photopolymerization 3D printing. The established synthesis route enables the gradual substitution of fossil-based raw materials with bio-based alternatives. The acid number, color and viscosity of the bio-based acrylic resins are characterized and photocurable formulations are prepared by adding a radical photoinitiator. The photopolymerization kinetics, and thermomechanical and mechanical properties of the photopolymers are investigated as a function of the resin structure and benchmarked against a commercially available petroleum-based counterpart. Finally, the processability of the new bio-based resins via digital light processing 3D printing is demonstrated and test specimens are successfully 3D printed with a resolution in the millimeter range.

From Unregulated Networks to Designed Microstructures: Introducing Heterogeneity at Different Length Scales in Photopolymers for Additive Manufacturing

Photopolymers have been optimized as protective and decorative coating materials for decades. However, with the rise of additive manufacturing technologies, vat photopolymerization has unlocked the use of photopolymers for three-dimensional objects with new material requirements. Thus, the originally highly cross-linked, amorphous architecture of photopolymers cannot match the expectations for modern materials anymore, revealing the largely unanswered question of how diverse properties can be achieved in photopolymers. Herein, we review how microstructural features in soft matter materials should be designed and implemented to obtain high performance materials. We then translate these findings into chemical design suggestions for enhanced printable photopolymers. Based on this analysis, we have found microstructural heterogenization to be the most powerful tool to tune photopolymer performance. By combining the chemical toolbox for photopolymerization and the analytical toolbox for microstructural characterization, we examine current strategies for physical heterogenization (fillers, inkjet printing) and chemical heterogenization (semicrystalline polymers, block copolymers, interpenetrating networks, photopolymerization induced phase separation) of photopolymers and put them into a material scientific context to develop a roadmap for improving and diversifying photopolymers' performance.

Dynamic Thermosetting Resins with Synergistic Enhanced Strength and Toughness through Combination with Rigid and Soft Microdomains

Preparation of materials that possess highly strong and tough properties simultaneously is a great challenge. Thermosetting resins as a type of widely used polymeric materials without synergistic strength and toughness limit their applications in some special fields. In this report, an effective strategy to prepare thermosetting resins with synergistic strength and toughness, is presented. In this method, the soft and rigid microspheres with dynamic hemiaminal bonds are fabricated first, followed by hot-pressing to crosslink at the interfaces. Specifically, the rigid or soft microspheres are prepared via precipitation polymerization. After hot-pressing, the resulting rigid-soft blending materials exhibit superior strength and toughness, simultaneously. As compared with the precursor rigid or soft materials, the toughness of the rigid-soft blending films (RSBFs) is improved to 240% and 2100%, respectively, while the strength is comparable to the rigid precursor. As compared with the traditional crushing, blending, and hot-pressing of rigid or soft materials to get the nonuniform materials, the strength and toughness of the RSBFs are improved to 168% and 255%, respectively. This approach holds significant promise for the fabrication of polymer thermosets with a unique combination of strength and toughness.

3D Printing of Self-Healing Materials

This review article presents a comprehensive overview of the latest advances in the field of 3D printable structures with self-healing properties. Three-dimensional printing (3DP) is a versatile technology that enables the rapid manufacturing of complex geometric structures with precision and functionality not previously attainable. However, the application of 3DP technology is still limited by the availability of materials with customizable properties specifically designed for additive manufacturing. The addition of self-healing properties within 3D printed objects is of high interest as it can improve the performance and lifespan of structural components, and even enable the mimicking of living tissues for biomedical applications, such as organs printing. The review will discuss and analyze the most relevant results reported in recent years in the development of self-healing polymeric materials that can be processed via 3D printing. After introducing the chemical and physical self-healing mechanism that can be exploited, the literature review here reported will focus in particular on printability and repairing performances. At last, actual perspective and possible development field will be critically discussed.

Technological Advancement and Trend in Selective Bioanalytical Sample Extraction through State of the Art 3-D Printing Techniques Aiming 'Sorbent Customization as per need'

The inherent complexity of biological matrices and presence of several interfering substances in biological samples make them unsuitable for direct analysis. An effective sample preparation technique assists in analyte enrichment, improving selectivity and sensitivity of bioanalytical method. Because of several key benefits of employing 3D printed sorbent in sample extraction, it has recently gained popularity across a variety of industries. Applications for 3D printing in the field of bioanalytical research have grown recently, particularly in the areas of miniaturization, (bio)sensing, sample preparation, and separation sciences. Due to the high expense of the solid phase microextraction cartridge, researcher approaches in-lab production of sorbent material for the extraction of analyte from biological samples. Owing to its distinct advantages such as low costs, automation capabilities, capacity to produce products in a variety of shapes, and reduction of tedious steps of sample preparation, 3D printed sorbents are gaining increased attention in the field of bioanalysis. It is also reported to offer high selectivity and assist in achieving a much lower limit of detection. In this review, we have discussed current advancements in different types of 3D printed sorbents, production methods, and their applications in the field of bioanalytical sample preparation.

Extrusion-Based 3D Printing of Photocrosslinkable Chitosan Inks

Photocuring of chitosan has shown great promise in the extrusion-based 3D printing of scaffolds for advanced biomedical and tissue engineering applications. However, the poor mechanical stability of methacrylated chitosan photocuring ink restricts its applicability. The inclusion of co-networks by means of simultaneous polycomplex formation is an effective method by which to solve this drawback, but the formed hydrogel inks are not printable. This work aims to develop new photocurable chitosan inks based on the simultaneous photocrosslinking of methacrylated chitosan (CHIMe) with N,N'-methylenebisacrylamide, polyethylene glycol diacrylate, and acrylic acid to be applied in extrusion 3D printing. Interestingly, the polycomplex co-network corresponding to the acrylic-acid-based ink could be successfully printed by the here-presented simultaneous photocuring strategy. Further, the conversion of photocrosslinking was studied via photo-DSC analyses that revealed a clear dependence on the chemical structure of the employed crosslinking agents (from 40 to ~100%). In addition, the mechanical and rheological properties of the photocured hydrogels were comparatively studied, as well as the printing quality of the extruded scaffolds. The newly developed chitosan photocurable inks demonstrated extrusion printability (squareness ~0.90; uniformity factor ~0.95) and tunable mechanical properties (Young modulus 14-1068 Pa) by means of different crosslinking approaches according to the chemical architecture of the reactive molecules employed. This work shows the great potential of photocrosslinkable chitosan inks.

Measured and simulated mechanical properties of additively manufactured matrix-inclusion multimaterials fabricated by material jetting

Modern additive manufacturing enables the simultaneous processing of different materials during the printing process. While multimaterial 3D printing allows greater freedom in part design, the prediction of the mix-material properties becomes challenging. One type of multimaterials are matrix-inclusion composites, where one material contains inclusions of another material. Aim of this study was to develop a method to predict the uniaxial Young's modulus and Poisson's ratio of material jetted matrix-inclusion composites by a combination of simulations and experimental data.Fifty samples from commercially available materials in their pure and matrix-inclusion mixed forms, with cubic inclusions, have been fabricated using material jetting and mechanically characterized by uniaxial tensile tests. Multiple simulation approaches have been assessed and compared to the measurement results in order to find and validate a method to predict the multimaterials' properties. Optical coherence tomography and microscopy was used to characterize the size and structure of the multimaterials, compared to the design.The materials exhibited Young's moduli in the range of 1.4 GPa to 2.5 GPa. The multimaterial mixtures were never as stiff as the weighted volume average of the primary materials (up to [Formula: see text] softer for 45% RGD8530-DM inclusions in VeroClear matrix). Experimental data could be predicted by finite element simulations by considering a non-ideal contact stiffness between matrix and inclusion ([Formula: see text] for RGD8530-DM, [Formula: see text] for RGD8430-DM), and geometries of the printed inclusions that deviated from the design (rounded edge radii of [Formula: see text]m). Not considering this would lead to a difference of the estimation result of up to [Formula: see text]MPa (44%), simulating an inclusion volume fraction of 45% RGD8530-DM.Prediction of matrix-inclusion composites fabricated by multimaterial jetting printing, is possible, however, requires a priori knowledge or additional measurements to characterize non-ideal contact stiffness between the components and effective printed geometries, precluding therefore a simple multimaterial modelling.

Mechanical Properties' Strengthening of Photosensitive 3D Resin in Lithography Technology Using Acrylated Natural Rubber

Acrylated natural rubber (ANR) with various acrylate contents (0.0-3.5 mol%) was prepared from natural rubber as a raw material and then incorporated with commercial 3D resin to fabricate specimens using digital light processing. As a result, the utilization of ANR with 1.5 mol% acrylate content could provide the maximum improvement in stretchability and impact strength, approximately 155% and 221%, respectively, over using pure 3D resin, without significant deterioration of tensile modulus and mechanical strength. According to evidence from a scanning electron microscope, this might be due to the partial interaction between the dispersed small rubber particles and the resin matrix. Additionally, the glass-transition temperature of the 3D-printed sample shifted to a lower temperature by introducing a higher acrylate content in the ANR. Therefore, this work might offer a practical way to effectively enhance the properties of the fundamental commercial 3D resin and broaden its applications. It also makes it possible to use natural rubber as a bio-based material in light-based 3D printing.

Recent Advances in UV-Cured Encapsulation for Stable and Durable Perovskite Solar Cell Devices

The stability and durability of perovskite solar cells (PSCs) are two main challenges retarding their industrial commercialization. The encapsulation of PSCs is a critical process that improves the stability of PSC devices for practical applications, and intrinsic stability improvement relies on materials optimization. Among all encapsulation materials, UV-curable resins are promising materials for PSC encapsulation due to their short curing time, low shrinkage, and good adhesion to various substrates. In this review, the requirements for PSC encapsulation materials and the advantages of UV-curable resins are firstly critically assessed based on a discussion of the PSC degradation mechanism. Recent advances in improving the encapsulation performance are reviewed from the perspectives of molecular modification, encapsulation materials, and corresponding architecture design while highlighting excellent representative works. Finally, the concluding remarks summarize promising research directions and remaining challenges for the use of UV-curable resins in encapsulation. Potential solutions to current challenges are proposed to inspire future work devoted to transitioning PSCs from the lab to practical application.

Engineering Toughness in a Brittle Vinyl Ester Resin Using Urethane Acrylate for Additive Manufacturing

Thermosetting polymers tend to have a stiffness-toughness trade-off due to the opposing relationship of stiffness and toughness on crosslink density. We hypothesize that engineering the polymer network, e.g., by incorporating urethane oligomers, we can improve the toughness by introducing variations in crosslink density. In this work, we show that a brittle methacrylated Bis-GMA resin (known as DA2) is toughened by adding a commercial urethane acrylate resin (known as Tenacious) in different proportions. The formulations are 3D printed using a vat photopolymerization technique, and their mechanical, thermal, and fracture properties are investigated. Our results show that a significant amount of Tenacious 60% w/w is required to produce parts with improved toughness. However, mechanical properties drop when the Tenacious amount is higher than 60% w/w. Overall, our results show that optimizing the amount of urethane acrylate can improve toughness without significantly sacrificing mechanical properties. In fact, the results show that synergistic effects in modulus and strength exist at specific blend concentrations.

3D printing of ultra-high viscosity resin by a linear scan-based vat photopolymerization system

The current printing mechanism of the bottom-up vat photopolymerization 3D printing technique places a high demand on the fluidity of the UV-curable resin. Viscous high-performance acrylate oligomers are compounded with reactive diluents accordingly to prepare 3D printable UV-curable resins (up to 5000 cps of viscosity), yet original mechanical properties of the oligomers are sacrificed. In this work, an elaborated designed linear scan-based vat photopolymerization system is developed, allowing the adoption of printable UV-curable resins with high viscosity (> 600,000 cps). Briefly, this is realized by the employment of four rollers to create an isolated printing area on the resin tank, which enables the simultaneous curing of the resin and the detachment of cured part from the resin tank. To verify the applicability of this strategy, oligomer dominated UV-curable resin with great mechanical properties, but high viscosity is prepared and applied to the developed system. It is inspiring to find that high stress and strain elastomers and toughened materials could be facilely obtained. This developed vat photopolymerization system is expected to unblock the bottleneck of 3D printed material properties, and to build a better platform for researchers to prepare various materials with diversiform properties developed with 3D printing.

Recent Advances in 3D Printing of Photocurable Polymers: Types, Mechanism, and Tissue Engineering Application

The conversion of liquid resin into solid structures upon exposure to light of a specific wavelength is known as photopolymerization. In recent years, photopolymerization-based 3D printing has gained enormous attention for constructing complex tissue-specific constructs. Due to the economic and environmental benefits of the biopolymers employed, photo-curable 3D printing is considered an alternative method for replacing damaged tissues. However, the lack of suitable bio-based photopolymers, their characterization, effective crosslinking strategies, and optimal printing conditions are hindering the extensive application of 3D printed materials in the global market. This review highlights the present status of various photopolymers, their synthesis, and their optimization parameters for biomedical applications. Moreover, a glimpse of various photopolymerization techniques currently employed for 3D printing is also discussed. Furthermore, various naturally derived nanomaterials reinforced polymerization and their influence on printability and shape fidelity are also reviewed. Finally, the ultimate use of those photopolymerized hydrogel scaffolds in tissue engineering is also discussed. Taken together, it is believed that photopolymerized 3D printing has a great future, whereas conventional 3D printing requires considerable sophistication, and this review can provide readers with a comprehensive approach to developing light-mediated 3D printing for tissue-engineering applications.

Miscibility and Optimization of the Liquid Rubber Content in the Resins of Light-Cured Dental Composites

Fracture toughness is one of the main factors influencing the durability of light-cured composites used for dental restorations and fillings. One of the methods of increasing the fracture toughness is the modification of the matrix with liquid acrylonitrile-free liquid rubber. This study aimed to assess the miscibility of acrylonitrile-free liquid rubber with a blend of resins and their stability over time, and to determine the optimal amount of liquid rubber (LR) in the blend due to mechanical properties. Two blends of dimethacrylate resins were used: resin "F" composed of BisGMA (60 wt.%), TEGDMA (20 wt.%), BisEMA (10 wt.%) and UDMA (10 wt.%), and "C" resin containing BisGMA (40 wt.%), TEGDMA (40 wt.%), BisEMA (10 wt.%) and UDMA (10 wt.%). The modifier Hypro^® 2000X168LC VTB liquid rubber was used in at 1%, 2%, 3%, 4%, 5%, 10%, 15% and 20% by weight in the resin blend. The miscibility was assessed by microscopy. The fracture toughness, flexural strength and Young's modulus were determined in the bending test. The results showed that the solubility of the liquid rubber depends on the ratio of BisGMA/TEGDMA in the resins. In resins with 40 wt.% TEGDMA, the LR solubility was as high as 5%, while resins with 20 wt.% TEGDMA, the liquid rubber did not dissolve. The LR-resin mixtures showed good time stability, and no changes in the size or morphology of the rubber domains were found after 24 h of mixing. The maximum fracture toughness (2.46 MPa m^1/2) was obtained for 5 wt.% LR in resin F and for 15 wt.% LR in resin C (2.53 MPa m^1/2). The modification with liquid rubber resulted in an exponential reduction in both flexural strength and Young's modulus. The analysis of the results of the mechanical tests allowed us to determine the optimal amount of LR for both resins. For resin F it was 5.4 wt.%, and for resin C it was 8.3 wt.%. It can be stated that the optimal amount of liquid rubber increases with its solubility in the resin.

Vat Photopolymerization 3D-Printing of Dynamic Thiol-Acrylate Photopolymers Using Bio-Derived Building Blocks

As an energy-efficient additive manufacturing process, vat photopolymerization 3D-printing has become a convenient technology to fabricate functional devices with high resolution and freedom in design. However, due to their permanently crosslinked network structure, photopolymers are not easily reprocessed or repaired. To improve the environmental footprint of 3D-printed objects, herein, we combine the dynamic nature of hydroxyl ester links, undergoing a catalyzed transesterification at elevated temperature, with an acrylate monomer derived from renewable resources. As a sustainable building block, we synthesized an acrylated linseed oil and mixed it with selected thiol crosslinkers. By careful selection of the transesterification catalyst, we obtained dynamic thiol-acrylate resins with a high cure rate and decent storage stability, which enabled the digital light processing (DLP) 3D-printing of objects with a structure size of 550 µm. Owing to their dynamic covalent bonds, the thiol-acrylate networks were able to relax 63% of their initial stress within 22 min at 180 °C and showed enhanced toughness after thermal annealing. We exploited the thermo-activated reflow of the dynamic networks to heal and re-shape the 3D-printed objects. The dynamic thiol-acrylate photopolymers also demonstrated promising healing, shape memory, and re-shaping properties, thus offering great potential for various industrial fields such as soft robotics and electronics.

Microporous Structure Formation of Poly(methyl methacrylate) via Polymerization-Induced Phase Separation in the Presence of Poly(ethylene glycol)

It has been demonstrated that nano- or micro-structured polymeric materials have huge potential as advanced materials. However, most of the current fabricating methods have limitations either in cost or in size. Here, we investigate the bulk polymerization of methyl methacrylate in the presence of poly(ethylene glycol) (PEG). We found that phase separation occurs during bulk polymerization. After removal of PEG via sonication, microscopic structures of poly(methyl methacrylate), including porous structures, co-continuous monolith structures, or particle aggregation structures, are formed. These structures can be controlled by the amount of PEG added and the reaction temperature. The results are summarized in phase diagrams. The addition of PEG significantly affects the reaction kinetics. Phase separation is coupled with the reaction acceleration known as the Trommsdorff effect. As a result, the reaction completes in a shorter time when the PEG amount is higher. We demonstrate surface coating to fabricate an amphiphobic surface, repelling both water and oil. The methods presented here have the potential to fabricate microscopic structures in large areas cost-effectively.

Preparation of Polyurethane/Acrylate Composite Emulsion for Inkjet Printing

Water-borne polyurethane/acrylate (WPUA) emulsion was prepared through emulsion polymerization between vinyl terminated waterborne polyurethane (WPU) and methyl methacrylate (MMA) in this research. Thermogravimetric Analysis (TGA), transmission electron microscopy (TEM), contact angle analysis, and particle size distribution analysis were employed to investigate the performance of the prepared emulsion and coatings with various content of MMA content. The results demonstrated that the thermal resistance, water resistance, and hardness of the prepared WPUA coatings were enhanced by the introduction of the MMA monomer. The contact angle (CA) and particle size of WPUA emulsion increased with the increase of MMA content. Meanwhile, the water-borne inkjet printing ink was prepared using WPUA emulsion as binder resin, and the printing test result showed that the prepared inkjet ink has good printability and color rendering, indicating that WPUA emulsion has great application prospects in the field of inkjet printing.

A Review of Properties of Nanocellulose, Its Synthesis, and Potential in Biomedical Applications

Cellulose is the most venerable and essential natural polymer on the planet and is drawing greater attention in the form of nanocellulose, considered an innovative and influential material in the biomedical field. Because of its exceptional physicochemical characteristics, biodegradability, biocompatibility, and high mechanical strength, nanocellulose attracts considerable scientific attention. Plants, algae, and microorganisms are some of the familiar sources of nanocellulose and are usually grouped as cellulose nanocrystal (CNC), cellulose nanofibril (CNF), and bacterial nanocellulose (BNC). The current review briefly highlights nanocellulose classification and its attractive properties. Further functionalization or chemical modifications enhance the effectiveness and biodegradability of nanocellulose. Nanocellulose-based composites, printing methods, and their potential applications in the biomedical field have also been introduced herein. Finally, the study is summarized with future prospects and challenges associated with the nanocellulose-based materials to promote studies resolving the current issues related to nanocellulose for tissue engineering applications.

A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization

Additive manufacturing or 3D printing of materials is a prominent process technology which involves the fabrication of materials layer-by-layer or point-by-point in a subsequent manner. With recent advancements in additive manufacturing, the technology has excited a great potential for extension of simple designs to complex multi-material geometries. Vat photopolymerization is a subdivision of additive manufacturing which possesses many attractive features, including excellent printing resolution, high dimensional accuracy, low-cost manufacturing, and the ability to spatially control the material properties. However, the technology is currently limited by design strategies, material chemistries, and equipment limitations. This review aims to provide readers with a comprehensive comparison of different additive manufacturing technologies along with detailed knowledge on advances in multi-material vat photopolymerization technologies. Furthermore, we describe popular material chemistries both from the past and more recently, along with future prospects to address the material-related limitations of vat photopolymerization. Examples of the impressive multi-material capabilities inspired by nature which are applicable today in multiple areas of life are briefly presented in the applications section. Finally, we describe our point of view on the future prospects of 3D printed multi-material structures as well as on the way forward towards promising further advancements in vat photopolymerization.

Thermal expansion of free volume in "classic" and regulated dimethacrylates: photocured directly and via a mask to study pillar formation

The temperature dependence of free volume in dimethacrylates (poly2M), cured by direct irradiation (poly2M-A) or via a mask (poly2M-B), and in a thiol-based 2M sample (poly2M-co-EDDT), was investigated by positron annihilation lifetime spectroscopy (PALS) and dilatometry (DIL) to study the influence of thiol regulation on the microstructure via free volume characteristics. It was found that the free volume fraction as determined from experimental data by using the standard spherical approach for the hole shapes showed systematic differences from the analogous quantity as evaluated from the lattice-hole theory. Much better results were obtained for cylindrical holes, which expand 'anisotropically' in poly2M samples and 'isotropically' in the poly2M-co-EDDT resin. In addition, the hydrogen bond changes and the conversion of monomers in cured samples studied by near infra-red spectroscopy (NIR) revealed spectrum-structure correlations for the final cured thermosets.

UV-LED Curable Acrylic Films Containing Phosphate Glass Powder: Effect of the Filler Loading on the Thermal, Optical, Mechanical and Flame Retardant Properties

In this work, we thoroughly investigate the effects of the incorporation of a phosphate glass micrometric powder on the morphology, as well as on the thermal, optical, mechanical and flame retardant properties of UV-LED curable acrylic films. To this aim, the filler loading was changed within 10 and 50 wt.%. UV-LED initiated curing was selected as a fast and reliable system, as the standard UV-curing process was not suitable because of the presence of the glass powder that decreased the quantum efficiency during the UV exposure, hence preventing the transformation of the liquid system into a solid network. The glass powder slightly increased the glass transition temperature of the acrylic network, hence showing a limited effect on the chain segments mobility; besides, increasing filler loadings were responsible for a progressive decrease of the transparency of films, irrespective of a marginal effect on their refractive index. Conversely, the presence of increasing amounts of phosphate glass improved the thermal and thermo-oxidative stability of the cured products. Besides, phosphate glass was capable of remarkably enhancing the flame retardance of the acrylic network at 50 wt.% loading, which achieved self-extinction in vertical flame spread tests (and was V-0 rated). This formulation, as assessed by forced-combustion tests, also displayed a remarkable decrease of peak of Heat Release Rate and Total Heat Release (by 44 and 33%, respectively) and of Total Smoke Release and Specific Extinction Area (by 53 and 56%, respectively). Further, the filler promoted an increase of the stiffness and surface hardness of the films, at the expense of a decrease in ductility. All these findings may justify the potential use of these composite films as flame retardant coatings for different flammable substrates.

Preparation and Characterization of 3D-Printed Biobased Composites Containing Micro- or Nanocrystalline Cellulose

Stereolithography (SLA), one of the seven different 3D printing technologies, uses photosensitive resins to create high-resolution parts. Although SLA offers many advantages for medical applications, the lack of biocompatible and biobased resins limits its utilization. Thus, the development of new materials is essential. This work aims at designing, developing, and fully characterizing a bio-resin system (made of poly(ethylene glycol) diacrylate (PEGDA) and acrylated epoxidized soybean oil (AESO)), filled with micro- or nanocellulose crystals (MCC and CNC), suitable for 3D printing. The unfilled resin system containing 80 wt.% AESO was identified as the best resin mixture, having a biobased content of 68.8%, while ensuring viscosity values suitable for the 3D printing process (>1.5 Pa s). The printed samples showed a 93% swelling decrease in water, as well as increased tensile strength (4.4 ± 0.2 MPa) and elongation at break (25% ± 2.3%). Furthermore, the incorporation of MCC and CNC remarkably increased the tensile strength and Young’s modulus of the cured network, thus indicating a strong reinforcing effect exerted by the fillers. Lastly, the presence of the fillers did not affect the UV-light penetration, and the printed parts showed a high quality, thus proving their potential for precise applications.

Advances in Digital Light Processing of Hydrogels

Hydrogels, three-dimensional (3D) networks of hydrophilic polymers formed in water, are a significant type of soft matter used in fundamental and applied sciences. Hydrogels are of particular interest for biomedical applications, owing to their soft elasticity and good biocompatibility. However, the high water content and soft nature of hydrogels often make it difficult to process them into desirable solid forms. The development of 3D printing (3DP) technologies has provided opportunities for the manufacturing of hydrogels, by adopting a freeform fabrication method. Owing to its high printing speed and resolution, vat photopolymerization 3DP has recently attracted considerable interest for hydrogel fabrication, with digital light processing (DLP) becoming a widespread representative technique. Whilst acknowledging that other types of vat photopolymerization 3DP have also been applied for this purpose, we here only focus on DLP and its derivatives. In this review, we first comprehensively outline the most recent advances in both materials and fabrication, including the adaptation of novel hydrogel systems and advances in processing (e.g., volumetric printing and multimaterial integration). Secondly, we summarize the applications of hydrogel DLP, including regenerative medicine, functional microdevices, and soft robotics. To the best of our knowledge, this is the first time that either of these specific review focuses has been adopted in the literature. More importantly, we discuss the major challenges associated with hydrogel DLP and provide our perspectives on future trends. To summarize, this review aims to aid and inspire other researchers investigatng DLP, photocurable hydrogels, and the research fields related to them.

Tough Photo-Cross-Linked PCL-Hydroxyapatite Composites for Bone Tissue Engineering

Acrylate-based photo-cross-linked poly(ε-caprolactone) (PCL) tends to show low elongation and strength. Incorporation of osteo-inductive hydroxyapatite (HAp) further enhances this effect, which limits its applicability in bone tissue engineering. To overcome this, the thiol-ene click reaction is introduced for the first time in order to photo-cross-link PCL composites with 0, 10, 20, and 30 wt % HAp nanoparticles. It is demonstrated that the elongation at break and ultimate strength increase 10- and 2-fold, respectively, when the photopolymerization mechanism is shifted from a radical chain-growth (i.e., acrylate cross-linking) toward a radical step-growth polymerization (i.e., thiol-ene cross-linking). Additionally, it is illustrated that osteoblasts can attach to and proliferate on the surface of the photo-cross-linked PCL-HAp composites. Finally, the incorporation of HAp nanoparticles is shown to reduce the ALP activity of osteoblasts. Overall, thiol-ene cross-linked PCL-HAp composites can be considered as promising potential materials for bone tissue engineering.

Covalently integrated silica nanoparticles in poly(ethylene glycol)-based acrylate resins: thermomechanical, swelling, and morphological behavior

Nanocomposites integrate functional nanofillers into viscoelastic matrices for electronics, lightweight structural materials, and tissue engineering. Herein, the effect of methacrylate-functionalized (MA-SiO₂) and vinyl-functionalized (V-SiO₂) silica nanoparticles on the thermal, mechanical, physical, and morphological characteristics of poly(ethylene glycol) (PEG) nanocomposites was investigated. The gel fraction of V-SiO₂ composites decreases upon addition of 3.8 wt% but increases with further addition (>7.4 wt%) until it reaches a plateau at 10.7 wt%. The MA-SiO₂ induced no significant changes in gel fraction and both V-SiO₂ and MA-SiO₂ nanoparticles had a negligible impact on the nanocomposite glass transition temperature and water absorption. The Young's modulus and ultimate compressive stress increased with increasing nanoparticle concentration for both nanoparticles. Due to the higher crosslink density, MA-SiO₂ composites reached a maximum mechanical stress at a concentration of 7.4 wt%, while V-SiO₂ composites reached a maximum at a concentration of 10.7 wt%. Scanning electron microscopy, transmission electron microscopy, and small-angle X-ray scattering revealed a bimodal size distribution for V-SiO₂ and a monomodal size distribution for MA-SiO₂. Although aggregates were observed for both nanoparticle surface treatments, V-SiO₂ dispersion was poor while MA-SiO₂ were generally well-dispersed. These findings lay the framework for silica nanofillers in PEG-based nanocomposites for advanced manufacturing applications.