Bio-based reactive diluents as sustainable replacements for styrene in MAESO resin

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.

Recent advances in lignin-based 3D printing materials: A mini-review

With the growing global population and rapid economic development, the demand for energy and raw materials is increasing, and the supply of fossil resources as the main source of energy and raw materials has reached a critical juncture. However, our overexploitation and overconsumption of fossil resources have led to serious problems, including environmental pollution, climate change, and ecosystem destruction. In the face of these challenges, we must recognize the negative impacts of the shortage of fossil resources and actively seek sustainable alternative sources of energy and resources to protect our environment and sustainable development in the future. Three-dimensional (3D) printing, an additive manufacturing technology, has been used in many fields to manufacture complex and high-precision products. While traditional manufacturing processes typically produce large amounts of waste and emissions that are harmful to the environment, 3D printing is much more energy efficient compared to traditional manufacturing methods, which helps to lower energy costs and reduce reliance on non-renewable energy sources. The development of low-carbon and environmentally friendly 3D printing materials can help to reduce carbon emissions and environmental pollution and realize the goal of sustainable development. Lignin, as the second largest renewable green biomass resource after cellulose, has great potential for manufacturing low-carbon and environmentally friendly 3D printing materials. This review presents some recent studies on the applications of lignin and its derivatives in photo-curing 3D printing, including the preparation and performance of lignin-based photosensitive prepolymers, lignin-based reactive diluents, lignin-based photo-initiators, and lignin-based additive. This review also provides recent studies on the preparation and performance of lignin-based thermoplastic polymer for Fused Deposition Modeling (FDM) 3D printing. Finally, the future challenges and industrialization prospects of lignin-based 3D printing materials are discussed.

Engineering an All-Biobased Solvent- and Styrene-Free Curable Resin

The sustainable production of polymers and materials derived from renewable feedstocks such as biomass is vital to addressing the current climate and environmental challenges. In particular, finding a replacement for current widely used curable resins containing undesired components with both health and environmental issues, such as bisphenol-A and styrene, is of great interest and vital for a sustainable society. In this work, we disclose the preparation and fabrication of an all-biobased curable resin. The devised resin consists of a polyester component based on fumaric acid, itaconic acid, 2,5-furandicarboxylic acid, 1,4-butanediol, and reactive diluents acting as both solvents and viscosity enhancers. Importantly, the complete process was performed solvent-free, thus promoting its industrial applications. The cured biobased resin demonstrates very good thermal properties (stable up to 415 °C), the ability to resist deformation based on the high Young's modulus of ∼775 MPa, and chemical resistance based on the swelling index and gel content. We envision the disclosed biobased resin having tailorable properties suitable for industrial applications.

Fully bio-based and intrinsically flame retardant unsaturated polyester cross-linked with isosorbide-based diluents

Unsaturated polyester resins (UPR) are composed of prepolymers and styrene diluents, while the former are produced by co-polycondensation between diol, unsaturated diacid and saturated diacid. In this work, bio-based UPR prepolymers were synthesized from bio-based oxalic acid, itaconic acid, and ethylene glycol, which were then diluted with bio-based isosorbide methacrylate (MI). Meanwhile, the phenylphosphonate were introduced into the molecular chains of prepolymers to achieve intrinsic flame retardancy of bio-based UPR. The potential of the reactive MI diluents as substitutes of volatile styrene, was also assessed through the volatility test, curing kinetics and gel contents analysis. For UPR materials with styrene diluents, the UPR materials can achieve UL-94 V0 level and the 28% of limiting oxygen index (LOI) with 2.63 wt% of phosphorus contents. By contrast, the UPR materials with MI diluents can reach UL-94 V0 level with only 2.14 wt% of phosphorus contents. As the phosphorus contents were further increased to 2.63 wt%, UPR materials can achieve highest 29%, while the peak of heat release rate (PHRR) and total heat release (THR) were decreased by 68.01% and 48.62%, respectively. The Flame Retardancy Index (FRI) was also used to comprehensively evaluate the flame retardant performance of UPR composites. Compared with neat UPR, the composites with MI diluents and phosphorus containing structures increased from 1.00 to 6.46. The mechanism for improved flame retardancy was analyzed from gaseous and condensed phase. Additionally, the tensile strengths of bio-based UPR materials with styrene and MI diluents were studied. This work provides an effective method to prepared high-performance and fully bio-based UPR materials with improved flame retardant properties and safety application of reactive diluents.

Sustainable near UV-curable acrylates based on natural phenolics for stereolithography 3D printing

Photocured polymers have recently gained tremendous interest for a wide range of applications especially industrial prototyping/additive manufacturing. This work aims to develop natural phenolic-based (meth)acrylates to expand the use of sustainable and mechanically robust 3D printable formulations.