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.

Optimization of the Poly(glycerol citraconate) Synthesis Using the Box-Behnken Design

This work aimed to obtain poly(glycerol citraconate) (PGCitrn) for biomedical applications, analyze the obtained polyester by spectroscopic methods, and optimize its preparation. Polycondensation reactions of glycerol and citraconic anhydride were carried out. It was provided that the results in the reaction are oligomers of poly(glycerol citraconate). Optimization studies were carried out based on the Box-Behnken design. The input variables in this plan were the ratio of functional groups, temperature, and time and occurrence in coded form: -1, 0, or 1. Three output variables were optimized: the degree of esterification, the percentage of Z-mers, and the degree of carboxyl group conversion; they were determined by titration and spectroscopic methods. The optimization criterion was to maximize the values of output variables. A mathematical model and an equation describing it were determined for each output variable. The models predicted the experimental results well. An experiment was conducted under determined optimal conditions. The experimental results were very close to the calculated values. Poly(glycerol citraconate) oligomers with an esterification degree of 55.2%, a Z-mer content of 79.0%, and a degree of rearrangement of carboxyl groups of 88.6% were obtained. The obtained PGCitrn can serve as a component of an injectable implant. The obtained material can be used to produce nonwoven fabrics (with the addition of PLLA, for example), which can be subjected to a cytotoxicity test which can then serve as a dressing material.

Recent Advances in the Enzymatic Synthesis of Polyester

Polyester is a kind of polymer composed of ester bond-linked polybasic acids and polyol. This type of polymer has a wide range of applications in various industries, such as automotive, furniture, coatings, packaging, and biomedical. The traditional process of synthesizing polyester mainly uses metal catalyst polymerization under high-temperature. This condition may have problems with metal residue and undesired side reactions. As an alternative, enzyme-catalyzed polymerization is evolving rapidly due to the metal-free residue, satisfactory biocompatibility, and mild reaction conditions. This article presented the reaction modes of enzyme-catalyzed ring-opening polymerization and enzyme-catalyzed polycondensation and their combinations, respectively. In addition, the article also summarized how lipase-catalyzed the polymerization of polyester, which includes (i) the distinctive features of lipase, (ii) the lipase-catalyzed polymerization and its mechanism, and (iii) the lipase stability under organic solvent and high-temperature conditions. In addition, this article also focused on the advantages and disadvantages of enzyme-catalyzed polyester synthesis under different solvent systems, including organic solvent systems, solvent-free systems, and green solvent systems. The challenges of enzyme optimization and process equipment innovation for further industrialization of enzyme-catalyzed polyester synthesis were also discussed in this article.

Polymer Chemistry Applications of Cyrene and its Derivative Cygnet 0.0 as Safer Replacements for Polar Aprotic Solvents

This study explores a binary solvent system composed of biobased Cyrene and its derivative Cygnet 0.0 for application in membrane technology and in biocatalytic synthesis of polyesters. Cygnet-Cyrene blends could represent viable replacements for toxic polar aprotic solvents. The use of a 50 wt % Cygnet-Cyrene mixture makes a practical difference in the production of flat sheet membranes by nonsolvent-induced phase separation. New polymeric membranes from cellulose acetate, polysulfone, and polyimide are manufactured by using Cyrene, Cygnet 0.0, and their blend. The resultant membranes have different morphology when the solvent/mixture and temperature of the casting solution change. Moreover, Cyrene, Cygnet 0.0, and Cygnet-Cyrene are also explored for substituting diphenyl ether for the biocatalytic synthesis of polyesters. The results indicate that Cygnet 0.0 is a very promising candidate for the enzymatic synthesis of high molecular weight polyesters.

Enzyme-catalyzed synthesis of malonate polyesters and their use as metal chelating materials

Following the environmental problems caused by non-degradable plastics there is a need to synthesise greener and more sustainable polymers. In this work we describe, for the first time, the facile enzyme-catalysed synthesis of linear polyesters using dimethyl malonate as the diester. These polymers, containing a different aliphatic diol component (C4, C6 or C8), were synthesised in solventless conditions using immobilized Candida antarctica lipase B as the biocatalyst. The potential of enzymes for catalysing this reaction is compared with the unsuccessful antimony- and titanium-catalysed synthesis (T > 150 °C). The application of the synthesized polymers as effective metal chelators in biphasic, green solvent systems was also described, together with the characterisation of the synthesised materials.

Enzymatic Synthesis of Polyesters and Their Bioapplications: Recent Advances and Perspectives

This article reviews the most important advances in the enzymatic synthesis of polyesters. In first place, the different processes of polyester enzymatic synthesis, i.e., polycondensation, ring opening, and chemoenzymatic polymerizations, and the key parameters affecting these reactions, such as enzyme, concentration, solvent, or temperature, are analyzed. Then, the latest articles on the preparation of polyesters either by direct synthesis or via modification are commented. Finally, the main bioapplications of enzymatically obtained polyesters, i.e., antimicrobial, drug delivery, or tissue engineering, are described. It is intended to point out the great advantages that enzymatic polymerization present to obtain polymers and the disadvantages found to develop applied materials.

Achievements and Trends in Biocatalytic Synthesis of Specialty Polymers from Biomass-Derived Monomers Using Lipases

New technologies for the conversion of biomass into high-value chemicals, including polymers and plastics, is a must and a challenge. The development of green processes in the last decade involved a continuous increase of the interest towards the synthesis of polymers using in vitro biocatalysis. Among the remarkable diversity of new bio-based polymeric products meeting the criteria of sustainability, biocompatibility, and eco-friendliness, a wide range of polyesters with shorter chain length were obtained and characterized, targeting biomedical and cosmetic applications. In this review, selected examples of such specialty polymers are presented, highlighting the recent developments concerning the use of lipases, mostly in immobilized form, for the green synthesis of ε-caprolactone co-polymers, polyesters with itaconate or furan units, estolides, and polyesteramides. The significant process parameters influencing the average molecular weights and other characteristics are discussed, revealing the advantages and limitations of biocatalytic processes for the synthesis of these bio-based polymers.

Highlight on the Mechanism of Linear Polyamidoamine Degradation in Water

This paper aims at elucidating the degradation mechanism of linear polyamidoamines (PAAs) in water. PAAs are synthesized by the aza-Michael polyaddition of prim-monoamines or bis-sec-amines with bisacrylamides. Many PAAs are water-soluble and have potential for biotechnological applications and as flame-retardants. PAAs have long been known to degrade in water at pH ≥ 7, but their degradation mechanism has never been explored in detail. Filling this gap was necessary to assess the suitability of PAAs for the above applications. To this aim, a small library of nine PAAs was expressly synthesized and their degradation mechanism in aqueous solution studied by 1H-NMR in different conditions of pH and temperature. The main degradation mechanism was in all cases the retro-aza-Michael reaction triggered by dilution but, in some cases, hints were detected of concurrent hydrolytic degradation. Most PAAs were stable at pH 4.0; all degraded at pH 7.0 and 9.0. Initially, the degradation rate was faster at pH 9.0 than at pH 7.0, but the percent degradation after 97 days was mostly lower. In most cases, at pH 7.0 the degradation followed first order kinetics. The degradation rates mainly depended on the basicity of the amine monomers. More basic amines acted as better leaving groups.

Straightforward Synthetic Protocol to Bio-BasedUnsaturated Poly(ester amide)s from Itaconic Acidwith Thixotropic Behavior

In the field of polymer chemistry, tremendous efforts have been made over the last decade to replace petrochemical monomers with building blocks from renewable resources. In this respect, itaconic acid has been used as an alternative to acrylic acid or maleic acid in unsaturated polyesters for thermal or UV-curing applications. However, examples of poly(ester amide)s from itaconic acid are scarce. Under standard polycondensation reactions, the presence of free amines leads to aza-Michael addition reactions at the α,β-unsaturated double bond of the itaconic acid and isomerization reactions to mesaconic acid. Both reactions make the resulting materials useless as UV-curing polymer resins. To avoid these undesired side reactions, we herein report the use of preformed, well-defined diols containing internal amide bonds. The resulting unsaturated poly(ester amide) resins were analyzed before and after UV-induced crosslinking. Viscosity measurements revealed a strong thixotropic behavior induced by the amide groups, which is usually not detected in structurally similar polyester resins.

First Example of Unsaturated Poly(Ester Amide)s Derived From Itaconic Acid and Their Application as Bio-Based UV-Curing Polymers

Recently, itaconic acid has drawn considerable attention as a novel radical-curing building block for polyester resins. These bio-based materials have been used in thermal, as well as ultra violet (UV) curing applications, such as printing inks or coatings. Poly(ester amide)s from itaconic acid could be very interesting, as the amide group could alter the properties of the resins as well as cured materials. However, standard polycondensation reactions with diamines are not possible with itaconic acid as the amines preferably react via an aza-Michael addition at the α,β-unsaturated double bond. Therefore, alternative and more elaborate synthetic strategies have to be developed. Herein, we present two different synthetic strategies to poly(ester amide)s from itaconic acid that circumvent the addition reaction of the amines. This is in both cases done by a pre-reaction to form stable amide building blocks that are then reacted with itaconic acid or polyesters derived thereof. The structural composition and the properties of the resin are characterized, and the UV-curing reactivity is examined. All properties are compared to corresponding polyesters from itaconic acid.

Thermal Upgrade of Enzymatically Synthesized Aliphatic and Aromatic Oligoesters

The enzymatic synthesis of polyesters in solventless systems is an environmentally friendly and sustainable method for synthetizing bio-derived materials. Despite the greenness of the technique, in most cases only short oligoesters are obtained, with limited practical applications or requiring further chemical processing for their elongation. In this work, we present a catalyst-free thermal upgrade of enzymatically synthesized oligoesters. Different aliphatic and aromatic oligoesters were synthesized using immobilized Candida antarctica lipase B (iCaLB) as the catalyst (70 °C, 24 h) yielding poly(1,4-butylene adipate) (PBA, M_w = 2200), poly(1,4-butylene isophthalate) (PBI, M_w = 1000), poly(1,4-butylene 2,5-furandicarboxylate) (PBF, M_w = 600), and poly(1,4-butylene 2,4-pyridinedicarboxylate) (PBP, M_w = 1000). These polyesters were successfully thermally treated to obtain an increase in M_w of 8.5, 2.6, 3.3, and 2.7 folds, respectively. This investigation focused on the most successful upgrade, poly(1,4-butylene adipate), then discussed the possible effect of di-ester monomers as compared to di-acids in the thermally driven polycondensation. The herein-described two-step synthesis method represents a practical and cost-effective way to synthesize higher-molecular-weight polymers without the use of toxic metal catalysts such as titanium(IV) tert-butoxide, tin(II) 2-ethylhexanoate, and in particular, antimony(IV) oxide. At the same time, the method allows for the extension of the number of reuses of the biocatalyst by preventing its exposure to extreme denaturating conditions.

Cascade aza-Michael Addition-Cyclizations; Toward Renewable and Multifunctional Carboxylic Acids for Melt-Polycondensation

Although the aza-Michael addition reaction on various unsaturated (di-)carboxylic acids and esters of, for example, itaconic acid, is well-known, the consecutive cyclization reaction has not received much attention in literature. The products of this aza-Michael cascade reaction, being mono- or di-carboxylic acid or ester functionalized N-alkyl-pyrrolidone structures, prove interesting for melt-polycondensation reactions as they exhibit excellent stability at elevated temperatures. In other words, this reaction is a toolbox for the generation of renewable monomers and, in turn, polymers with tunable physiological properties. Therefore, this work provides an overview of the state-of-the-art of the cascade aza-Michael addition-cyclization reactions on biobased unsaturated acids and esters, and their use in polymerization reactions. Furthermore, we extend this overview with the cascade aza-Michael addition-cyclization reaction of trans-trimethyl aconitate with di-amines to form a tetra-functional N-alkyl-bis-(pyrrolidone dimethylcarboxylate), which exhibits excellent thermal stability and could effectively be used as monomer in polycondensation reactions. Importantly, the aza-Michael addition reaction between primary amines and trans-trimethyl aconitate can be considered a click-reaction; it proceeds quantitatively within minutes under ambient conditions and follows the principles of green chemistry.

Radical addition polymerization: Enzymatic template-free synthesis of conjugated polymers and their nanostructure fabrication

Conjugated polymers are attractive for many applications due to their unique properties. Their molecular structure can easily be tuned, making them suitable for an enormous number of specific applications. Conjugated polymers have the potential to achieve electrical properties similar to those of noncrystalline inorganic semiconductors; however, their chemical structure is much more complex and somewhat resembles that of biomacromolecules. The molecular conformation and interactions of conjugated polymers play an important role in their functionality. The use of enzymes has emerged as a highly valuable alternative method to synthesize these polymers and is very useful in the fabrication of their nanostructures. Here, we present established strategies for the synthesis of conjugated polymers in template-free systems that do not interfere with the preparation of their nanostructures. These strategies are based on the use of peroxidases (class III; EC 1.11.1.7, donor: hydrogen peroxide oxidoreductase), which are enzymes that have the ability to catalyze the oxidation of a number of compounds (including aromatics such as aniline, pyrrole, thiophene and some of their derivatives), in the presence of hydrogen peroxide, to obtain conjugated polymers.

Integrating computational and experimental methods for efficient biocatalytic synthesis of polyesters

The research on biocatalyzed polycondensation has delivered an array of polyesters having molecular weights below 20,000gmol^-1 but characterized by controlled structures and desired functionalities. Their unique catalytic efficiency under mild conditions enables enzymes to catalyze the polycondensation of monomers bearing labile lateral moieties that can be easily accessed via post-polymerization modifications. Despite this great potential, nowadays biocatalysts are not employed for polycondensation on industrial scale due to some bottlenecks related to the formulation of biocatalysts and the process configuration, which make the enzymatic technology non-economic. Recycling the enzymatic catalysts is not only a matter of producing an active and robust formulation, but it also requires the optimal integration of such biocatalyst within a specific reactor and process configuration that must enable efficient mass-transfer while preserving the integrity of the enzymatic preparation. In this chapter, we describe examples of integrated experimental-computational approaches for the rational planning and implementation of enzymatic polycondensation using lipase B from Candida antarctica and cutinase 1 from Thermobifida cellulosilytica. They rely on molecular visualization, molecular modeling and chemometrics, which are methods requiring very modest computational power and approachable by operators who do not have specific computational background. The examples also address the sustainability issue, by describing solvent-free processes involving bio-based monomers and biocatalysts immobilized on renewable carriers.

One-Pot Synthesis of Unsaturated Polyester Bioelastomer with Controllable Material Curing for Microscale Designs

Synthetic polyester elastomeric constructs have become increasingly important for a range of healthcare applications, due to tunable soft elastic properties that mimic those of human tissues. A number of these constructs require intricate mechanical design to achieve a tunable material with controllable curing. Here, the synthesis and characterization of poly(itaconate-co-citrate-co-octanediol) (PICO) is presented, which exhibits tunable formation of elastomeric networks through radical crosslinking of itaconate in the polymer backbone of viscous polyester gels. Through variation of reaction times and monomer molar composition, materials with modulation of a wide range of elasticity (36-1476 kPa) are generated, indicating the tunability of materials to specific elastomeric constructs. This correlated with measured rapid and controllable gelation times. As a proof of principle, scaffold support for cardiac tissue patches is developed, which presents visible tissue organization and viability with appropriate elastomeric support from PICO materials. These formulations present potential application in a range of healthcare applications with requirement for elastomeric support with controllable, rapid gelation under mild conditions.

Improving the Post-polymerization Modification of Bio-Based Itaconate Unsaturated Polyesters: Catalyzing Aza-Michael Additions With Reusable Iodine on Acidic Alumina

Bio-based platform molecules such as itaconic, fumaric, and muconic acid offer much promise in the formation of sustainable unsaturated polyester resins upon reaction with suitable diols and polyols. The C=C bonds present in these polyester chains allows for post-polymerization modification and such moieties are conventionally utilized in curing processes during the manufacture of coatings. The C=C modification sites can also act as points to add useful pendants which can alter the polymers final properties such as glass transition temperature, biodegradability, hardness, polarity, and strength. A commonly observed modification is the addition of secondary amines via an aza-Michael addition. Conventional procedures for the addition of amines onto itaconate polyesters require reaction times of several days as a result of undesired side reactions, in particular, the formation of the less reactive mesaconate regioisomer. The slow reversion of the mesaconate back to itaconate, followed by subsequent amine addition, is the primary reason for such extended reaction times. Herein we report our efforts toward finding a suitable catalyst for the aza-Michael addition of diethylamine onto a model substrate, dimethyl itaconate, with the aim of being able to add amine onto the itaconate units without excessive regioisomerization to the inactive mesaconate. A catalyst screen showed that iodine on acidic alumina results in an effective, heterogeneous, reusable catalyst for the investigated aza-Michael addition. Extending the study further, itaconate polyester was prepared by Candida Antartica Lipase B (CaL-B) via enzymatic polytranesterification and subsequently modified with diethylamine using the iodine on acidic alumina catalyst, dramatically reducing the required length of reaction (>70% addition after 4 h). The approach represents a multidisciplinary example whereby biocatalytic polymerization is combined with chemocatalytic modification of the resultant polyester for the formation of useful bio-based polyesters.