3D Printable Non-Isocyanate Polyurethanes with Tunable Material Properties

Design, manufacturing and testing of a green non-isocyanate polyurethane prosthetic heart valve

The sole effective treatment for most patients with heart valve disease is valve replacement by implantation of mechanical or biological prostheses. However, mechanical valves represent high risk of thromboembolism, and biological prostheses are prone to early degeneration. In this work, we aim to determine the potential of novel environmentally-friendly non-isocyanate polyurethanes (NIPUs) for manufacturing synthetic prosthetic heart valves. Polyhydroxyurethane (PHU) NIPUs are synthesized via an isocyanate-free route, tested in vitro, and used to produce aortic valves. PHU elastomers reinforced with a polyester mesh show mechanical properties similar to native valve leaflets. These NIPUs do not cause hemolysis. Interestingly, both platelet adhesion and contact activation-induced coagulation are strongly reduced on NIPU surfaces, indicating low thrombogenicity. Fibroblasts and endothelial cells maintain normal growth and shape after indirect contact with NIPUs. Fluid-structure interaction (FSI) allows modeling of the ideal valve design, with minimal shear stress on the leaflets. Injection-molded valves are tested in a pulse duplicator and show ISO-compliant hydrodynamic performance, comparable to clinically-used bioprostheses. Poly(tetrahydrofuran) (PTHF)-NIPU patches do not show any evidence of calcification over a period of 8 weeks. NIPUs are promising sustainable biomaterials for the manufacturing of improved prosthetic valves with low thrombogenicity.

Design of 3D-Photoprintable, Bio-, and Hemocompatible Nonisocyanate Polyurethane Elastomers for Biomedical Implants

Polyurethanes (PUs) have adjustable mechanical properties, making them suitable for a wide range of applications, including in the biomedical field. Historically, these PUs have been synthesized from isocyanates, which are toxic compounds to handle. This has encouraged the search for safer and more environmentally friendly synthetic routes, leading today to the production of nonisocyanate polyurethanes (NIPUs). Among these NIPUs, polyhydroxyurethanes (PHUs) bear additional hydroxyl groups, which are particularly attractive for derivatizing and adjusting their physicochemical properties. In this paper, polyether-based NIPU elastomers with variable stiffness are designed by functionalizing the hydroxyl groups of a poly(propylene glycol)-PHU by a cyclic carbonate carrying a pendant unsaturation, enabling them to be post-photo-cross-linked with polythiols (thiol-ene). Elastomers with remarkable mechanical properties whose stiffness can be adjusted are obtained. Thanks to the unique viscous properties of these PHU derivatives and their short gel times observed by rheology experiments, formulations for light-based three-dimensional (3D) printing have been developed. Objects were 3D-printed by digital light processing with a resolution down to the micrometer scale, demonstrating their ability to target various designs of prime importance for personalized medicine. In vitro biocompatibility tests have confirmed the noncytotoxicity of these materials for human fibroblasts. In vitro hemocompatibility tests have revealed that they do not induce hemolytic effects, they do not increase platelet adhesion, nor activate coagulation, demonstrating their potential for future applications in the cardiovascular field.

Direct ink writing of biocompatible chitosan/non-isocyanate polyurethane/cellulose nanofiber hydrogels for wound-healing applications

The demand for new biocompatible and 3D printable materials for biomedical applications is on the rise. Ideally, such materials should exhibit either biodegradability or recyclability, possess antibacterial properties, and demonstrate remarkable biocompatibility with no cytotoxic effects. In this research, we synthesized biocompatible and 3D printable hydrogels tailored for biomedical applications, such as wound healing films, by combining antibacterial double-quaternized chitosan (DQC) with cystamine-based non-isocyanate polyurethane (NIPU-Cys) - a material renowned for enhancing both the flexibility and mechanical properties of the hydrogels. To improve the rheological behavior, swelling attributes, and printability, cellulose nanofibrils were introduced into the matrix. We investigated the impact of DQC on degradability, swelling capacity, rheological behavior, printability, and cell biocompatibility. The slightly cytotoxic nature associated with quaternary chitosan was evaluated, and the optimal concentration of DQC in the hydrogel was determined to ensure biocompatibility. The resulting hydrogels were found to be suitable materials for 3D printing via a direct ink writing technique (DIW), producing porous, biocompatible hydrogels endowed with valuable attributes suitable for various wound-healing applications.

Bioactive Polyurethane-Poly(ethylene Glycol) Diacrylate Hydrogels for Applications in Tissue Engineering

Polyurethanes (PUs) are a highly adaptable class of biomaterials that are among some of the most researched materials for various biomedical applications. However, engineered tissue scaffolds composed of PU have not found their way into clinical application, mainly due to the difficulty of balancing the control of material properties with the desired cellular response. A simple method for the synthesis of tunable bioactive poly(ethylene glycol) diacrylate (PEGDA) hydrogels containing photocurable PU is described. These hydrogels may be modified with PEGylated peptides or proteins to impart variable biological functions, and the mechanical properties of the hydrogels can be tuned based on the ratios of PU and PEGDA. Studies with human cells revealed that PU-PEG blended hydrogels support cell adhesion and viability when cell adhesion peptides are crosslinked within the hydrogel matrix. These hydrogels represent a unique and highly tailorable system for synthesizing PU-based synthetic extracellular matrices for tissue engineering applications.

Innovations in applications and prospects of non-isocyanate polyurethane bioplastics

Currently, conventional plastics are necessary for a variety of aspects of modern daily life, including applications in the fields of healthcare, technology, and construction. However, they could also contain potentially hazardous compounds like isocyanates, whose degradation has a negative impact on both the environment and human health. Therefore, researchers are exploring alternatives to plastic which is sustainable and environmentally friendly without compromising its mechanical and physical features. This review study highlights the production of highly eco-friendly bioplastic as an efficient alternative to non-biodegradable conventional plastic. Bioplastics are produced from various renewable biomass sources such as plant debris, fatty acids, and oils. Poly-addition of di-isocyanates and polyols is a technique employed over decades to produce polyurethanes (PUs) bioplastics from renewable biomass feedstock. The toxicity of isocyanates is a major concern with the above-mentioned approach. Novel green synthetic approaches for polyurethanes without using isocyanates have been attracting greater interest in recent years to overcome the toxicity of isocyanate-containing raw materials. The polyaddition of cyclic carbonates (CCs) and polyfunctional amines appears to be the most promising method to obtain non-isocyanate polyurethanes (NIPUs). This method results in the creation of polymeric materials with distinctive and adaptable features with the elimination of harmful compounds. Consequently, non-isocyanate polyurethanes represent a new class of green polymeric materials. In this review study, we have discussed the possibility of creating novel NIPUs from renewable feedstocks in the context of the growing demand for efficient and ecologically friendly plastic products.

Thermal and UV Curable Formulations of Poly(propylene glycol)-Poly(hydroxyurethane) Elastomers toward Nozzle-Based 3D Photoprinting

In this work, isocyanate-free formulations for poly(propylene glycol) polyurethane elastomers are studied. These formulations are based on poly(propylene glycol) end-capped by CO2-sourced cyclic carbonate (bisCC PPG) macromonomers able to react with amines leading to poly(hydroxyurethane)s. In order to obtain covalent networks, two curing approaches are studied. First, the direct thermally activated cross-linking of bisCC PPG with a mixture of various aliphatic or aromatic diamines and a triamine is investigated, and in particular the nature of the diamine on the mechanical properties. In the second approach, UV-activated formulations are developed by reacting bisCC PPG with allylamine followed by the addition of a trithiol by photoactivated thiol-ene reaction. The swelling tests show that both systems provide highly cross-linked polymer networks and complementary characterizations highlighted excellent mechanical properties. Thanks to the fast curing and adapted viscosity of the developed photoactive formulation, the latter was found suitable for use as a photoresin for 3D printing as demonstrated by printing a vaginal ring by a nozzle-based photoprinter.

Solvent-Free Design of Biobased Non-isocyanate Polyurethanes with Ferroelectric Properties

Increasing energy autonomy and lowering dependence on lithium-based batteries are more and more appealing to meet our current and future needs of energy-demanding applications such as data acquisition, storage, and communication. In this respect, energy harvesting solutions from ambient sources represent a relevant solution by unravelling these challenges and giving access to an unlimited source of portable/renewable energy. Despite more than five decades of intensive study, most of these energy harvesting solutions are exclusively designed from ferroelectric ceramics such as Pb(Zr,Ti)O3 and/or ferroelectric polymers such as polyvinylidene fluoride and its related copolymers, but the large implementation of these piezoelectric materials into these technologies is environmentally problematic, related with elevated toxicity and poor recyclability. In this work, we reveal that fully biobased non-isocyanate polyurethane-based materials could afford a sustainable platform to produce piezoelectric materials of high interest. Interestingly, these non-isocyanate polyurethanes (NIPUs) with ferroelectric properties could be successfully synthesized using a solvent-free reactive extrusion process on the basis of an aminolysis reaction between resorcinol bis-carbonate and different diamine extension agents. Structure-property relationships were established, indicating that the ferroelectric behavior of these NIPUs depends on the nanophase separation inside these materials. These promising results indicate a significant potential for fulfilling the requirements of basic connected sensors equipped with low-power communication technologies.

3D printing of inherently nanoporous polymers via polymerization-induced phase separation

3D printing offers enormous flexibility in fabrication of polymer objects with complex geometries. However, it is not suitable for fabricating large polymer structures with geometrical features at the sub-micrometer scale. Porous structure at the sub-micrometer scale can render macroscopic objects with unique properties, including similarities with biological interfaces, permeability and extremely large surface area, imperative inter alia for adsorption, separation, sensing or biomedical applications. Here, we introduce a method combining advantages of 3D printing via digital light processing and polymerization-induced phase separation, which enables formation of 3D polymer structures of digitally defined macroscopic geometry with controllable inherent porosity at the sub-micrometer scale. We demonstrate the possibility to create 3D polymer structures of highly complex geometries and spatially controlled pore sizes from 10 nm to 1000 µm. Produced hierarchical polymers combining nanoporosity with micrometer-sized pores demonstrate improved adsorption performance due to better pore accessibility and favored cell adhesion and growth for 3D cell culture due to surface porosity. This method extends the scope of applications of 3D printing to hierarchical inherently porous 3D objects combining structural features ranging from 10 nm up to cm, making them available for a wide variety of applications.

3D printing offers flexibility in fabrication of polymer objects but fabrication of large polymer structures with micrometer-sized geometrical features are challenging. Here, the authors introduce a method combining advantages of 3D printing and polymerization-induced phase separation, which enables formation of 3D polymer structures with controllable inherent porosity.

Poly(hydroxyurethane): catalytic applicability for the cyclic carbonate synthesis from epoxides and CO2

We have developed a synthetic methodology using poly(hydroxyurethane) as an organocatalyst for the chemical fixation of CO2 into epoxides, leading to the formation of five-membered cyclic carbonates with remarkably high selectivity and yields. The catalyzed reaction was applicable to various epoxides.

100th Anniversary of Macromolecular Science Viewpoint: Macromolecular Materials for Additive Manufacturing

Additive manufacturing (AM) has drawn tremendous attention as a versatile platform for the on-demand fabrication of objects with excellent spatial control of chemical compositions and complex architectures. The development of materials that are specifically designed for AM is highly desirable for a variety of applications ranging from personal healthcare, tissue engineering, biomedical devices, self-folding origami structures, and soft robotics. Polymeric macromolecules have received increasing attention due to a wide variety of materials, the versatility for novel chemistries, and the ability to tune chemical composition and architecture. This Viewpoint highlights the development of polymeric materials for direct-ink writing and vat photopolymerization for 3D printing applications. Recent chemical innovations and polymer architectures are overviewed, which also includes recent developments in responsive and adaptive objects from AM. Polymers for biological interface and sustainability in AM are also discussed.

Developing non-isocyanate urethane-methacrylate photo-monomers for 3D printing application

Urethane-methacrylate photo-monomers were prepared via a non-isocyanate route for the 3D printing application. The monomers were synthesized through reacting aliphatic amines, i.e. 1,6-hexanediamine, 1,4-butanediol bis(3-aminopropyl) ether, or n-butylamine, with cyclic carbonates, i.e. ethylene carbonate or propylene carbonate, followed by the methacrylation of the generated hydroxylurethanes. The effects of the chemical structure of monomers on their photo-reactivity and physicomechanical properties of the cured samples were studied. Propylene carbonate generated side methyl groups within the urethane block, which significantly limited the crystallization of the monomers resulting in high photo-reactivity (R_p,max = 6.59 × 10⁻² s⁻¹) and conversion (DBC_total = 85%). The ether bonds of 1,4-butanediol bis(3-aminopropyl) ether decreased the intermolecular hydrogen bonding between urethane blocks, which not only improved the photo-reactivity (R_p,max = 8.18 × 10⁻² s⁻¹) and conversion (DBC_total = 86%) of the monomer but led to a high crosslinking density (ν_c = 5140 mol m⁻³) and more flexibility for the cured sample. An ink was developed based on the monomers and successfully 3D printed on a digital light processing machine. In the absence of toxic isocyanates and tin compounds, the non-isocyanate route can be employed to develop urethane-methacrylates with desirable photo-reactivity and physicomechanical properties as good candidates to formulate inks for 3D printing of biomedical materials.

Synthesis of urethane-methacrylate photo-monomers via a non-isocyanate route for 3D printing of flexible biomedical materials.