Digital light processing 3D printing of modified liquid isoprene rubber using thiol-click chemistry

ROS-responsive hydrogels: from design and additive manufacturing to biomedical applications

Hydrogels with intricate 3D networks and high hydrophilicity have qualities resembling those of biological tissues, making them ideal candidates for use as smart biomedical materials. Reactive oxygen species (ROS) responsive hydrogels are an innovative class of smart hydrogels, and are cross-linked by ROS-responsive modules through covalent interactions, coordination interactions, or supramolecular interactions. Due to the introduction of ROS response modules, this class of hydrogels exhibits a sensitive response to the oxidative stress microenvironment existing in organisms. Simultaneously, due to the modularity of the ROS-responsive structure, ROS-responsive hydrogels can be manufactured on a large scale through additive manufacturing. This review will delve into the design, fabrication, and applications of ROS-responsive hydrogels. The main goal is to clarify the chemical principles that govern the response mechanism of these hydrogels, further providing new perspectives and methods for designing responsive hydrogel materials.

Photochemically Activated 3D Printing Inks: Current Status, Challenges, and Opportunities

3D printing with light is enabled by the photochemistry underpinning it. Without fine control over the ability to photochemically gate covalent bond formation by the light at a certain wavelength and intensity, advanced photoresists with functions spanning from on-demand degradability, adaptability, rapid printing speeds, and tailored functionality are impossible to design. Herein, recent advances in photoresist design for light-driven 3D printing applications are critically assessed, and an outlook of the outstanding challenges and opportunities is provided. This is achieved by classing the discussed photoresists in chemistries that function photoinitiator-free and those that require a photoinitiator to proceed. Such a taxonomy is based on the efficiency with which photons are able to generate covalent bonds, with each concept featuring distinct advantages and drawbacks.

Radical chemistry in polymer science: an overview and recent advances

Radical chemistry is one of the most important methods used in modern polymer science and industry. Over the past century, new knowledge on radical chemistry has both promoted and been generated from the emergence of polymer synthesis and modification techniques. In this review, we discuss radical chemistry in polymer science from four interconnected aspects. We begin with radical polymerization, the most employed technique for industrial production of polymeric materials, and other polymer synthesis involving a radical process. Post-polymerization modification, including polymer crosslinking and polymer surface modification, is the key process that introduces functionality and practicality to polymeric materials. Radical depolymerization, an efficient approach to destroy polymers, finds applications in two distinct fields, semiconductor industry and environmental protection. Polymer chemistry has largely diverged from organic chemistry with the fine division of modern science but polymer chemists constantly acquire new inspirations from organic chemists. Dialogues on radical chemistry between the two communities will deepen the understanding of the two fields and benefit the humanity.

Evaluation of flexible three-dimensionally printed occlusal splint materials: An in vitro study

OBJECTIVE

To evaluate and compare the mechanical properties, water sorption, water solubility, and degree of double bond conversion of three different commercially available three-dimensional (3D) printing resins used for the fabrication of flexible occlusal splints.

METHODS

A digital printer was used to generate specimens from the evaluated splint materials (KeySplint Soft, IMPRIMO LC Splint flex, and V-Print splint comfort). The specimens were equally divided and tested either dry or after water storage at 37 °C for 30 days. A three-point bending test was used to assess flexural strength, elastic modulus, and fracture toughness. A two-body wear test was performed using a dual-axis chewing simulator. Water sorption and water solubility were measured after 30 days. The degree of double bond conversion was determined by FTIR-spectrometry. All data for the evaluated properties were collected and statistically analyzed.

RESULTS

Both material and storage conditions had a significant effect on the flexural strength (P < 0.001), elastic modulus (P < 0.001), fracture toughness (P < 0.001), and wear (P < 0.001). The highest water sorption was noticed with IMPRIMO LC Splint flex (1.9 ± 0.0 %), while V-Print splint comfort displayed the lowest water solubility (0.2 ± 0.0 %). For the degree of conversion, it was statistically non-significant among the different materials (P = 0.087).

SIGNIFICANCE

Different flexible 3D-printed splints available in the market displayed variations in the evaluated properties and clinicians should consider these differences when choosing occlusal device materials. Among the tested flexible splint materials, KeySplint Soft had the greatest flexural strength, elastic modulus, fracture toughness, wear resistance, and degree of conversion. It also showed the lowest water sorption.

The Effects of Polyaniline Nanofibers and Graphene Flakes on the Electrical Properties and Mechanical Properties of ABS-like Resin Composites Obtained by DLP 3D Printing

Three-dimensional printing is regarded as a future-oriented additive manufacturing technology that is making significant contributions to the field of polymer processing. Among the 3D printing methods, the DLP (digital light processing) technique has attracted great interest because it requires a short printing time and enables high-quality printing through selective light curing of polymeric materials. In this study, we report a fabrication method for ABS-like resin composites containing polyaniline (PANI) nanofibers and graphene flakes suitable for DLP 3D printing. As-prepared ABS-like resin composite inks employing PANI nanofibers and graphene flakes as co-fillers were successfully printed, obtaining highly conductive and mechanically robust products with the desired shapes and different sizes through DLP 3D printing. The sheet resistance of the 3D-printed composites was reduced from 2.50 × 10¹⁵ ohm/sq (sheet resistance of pristine ABS-like resin) to 1.61 × 10⁶ ohm/sq by adding 3.0 wt.% of PANI nanofibers and 1.5 wt.% of graphene flakes. Furthermore, the AP3.0G1.5 sample (the 3D-printed composite containing 3.0 wt.% of PANI nanofibers and 1.5 wt.% of graphene flakes) exhibited 2.63 times (22.23 MPa) higher tensile strength, 1.47 times (553.8 MPa) higher Young's modulus, and 5.07 times (25.83%) higher elongation at break values compared to the pristine ABS-like resin with a tensile strength of 8.46 MPa, a Young's modulus of 376.6 MPa, and an elongation at break of 5.09%. Our work suggests the potential use of highly conductive and mechanically robust ABS-like resin composites in the 3D printing industry. This article not only provides optimized DLP 3D printing conditions for the ABS-like resin, which has both the advantages of the ABS resin and the advantages of a thermoplastic elastomer (TPE), but also presents the effective manufacturing process of ABS-like resin composites with significantly improved conductivity and mechanical properties.

Chemistry in light-induced 3D printing

In the last few years, 3D printing has evolved from its original niche applications, such as rapid prototyping and hobbyists, towards many applications in industry, research and everyday life. This involved an evolution in terms of equipment, software and, most of all, in materials. Among the different available 3D printing technologies, the light activated ones need particular attention from a chemical point of view, since those are based on photocurable formulations and in situ rapid solidification via photopolymerization. In this article, the chemical aspects beyond the preparation of a formulation for light-induced 3D printing are analyzed and explained, aiming at giving more tools for the development of new photocurable materials that can be used for the fabrication of innovative 3D printable devices.

Graphical abstract

Vat photopolymerization-based 3D printing of polymer nanocomposites: current trends and applications

The synthesis and manufacturing of polymer nanocomposites have garnered interest in recent research and development because of their superiority compared to traditionally employed industrial materials. Specifically, polymer nanocomposites offer higher strength, stronger resistance to corrosion or erosion, adaptable production techniques, and lower costs. The vat photopolymerization (VPP) process is a group of additive manufacturing (AM) techniques that provide the benefit of relatively low cost, maximum flexibility, high accuracy, and complexity of the printed parts. In the past few years, there has been a rapid increase in the understanding of VPP-based processes, such as high-resolution AM methods to print intricate polymer parts. The synergistic integration of nanocomposites and VPP-based 3D printing processes has opened a gateway to the future and is soon expected to surpass traditional manufacturing techniques. This review aims to provide a theoretical background and the engineering capabilities of VPP with a focus on the polymerization of nanocomposite polymer resins. Specifically, the configuration, classification, and factors affecting VPP are summarized in detail. Furthermore, different challenges in the preparation of polymer nanocomposites are discussed together with their pre- and post-processing, where several constraints and limitations that hinder their printability and photo curability are critically discussed. The main focus is the applications of printed polymer nanocomposites and the enhancement in their properties such as mechanical, biomedical, thermal, electrical, and magnetic properties. Recent literature, mainly in the past three years, is critically discussed and the main contributing results in terms of applications are summarized in the form of tables. The goal of this work is to provide researchers with a comprehensive and updated understanding of the underlying difficulties and potential benefits of VPP-based 3D printing of polymer nanocomposites. It will also help readers to systematically reveal the research problems, gaps, challenges, and promising future directions related to polymer nanocomposites and VPP processes.

Hybrid In Situ Reinforcement of EPDM Rubber Compounds Based on Phenolic Novolac Resin and Ionic Coagent

For the design of stretchable and flexible high-performing materials, the reinforcement of elastomeric grades plays a crucial role. State-of-the-art fillers such as carbon black benefit from a high reinforcement but often negatively affect the processing and mixing properties of rubber compounds. To overcome this drawback, the synergistic properties of hybrid in situ filler systems are studied for EPDM compounds comprising a phenol novolac resin and ionic coagents such as zinc (meth)acrylates (ZD(M)A. With the help of a combined novolac/ZD(M)A system, the compounds could be tailored in a unique way towards higher toughness and enhanced cross-link density. Further, the fracture surface of the EPDM–novolac compounds was analyzed by scanning electron microscopy, revealing a significant change of the morphology from rough and disordered to smooth and homogenous for samples with coagents. In addition, the results clearly showed that the introduction of ionic coagents is able to compensate shares of carbon black filler in the EPDM compound. The toughening of samples with zinc (meth)acrylates is attributed to the synergistic formation of an interpenetrating polymer-filler network by simultaneous covalent and ionic cross-linking.

Development of Liquid Diene Rubber Based Highly Deformable Interactive Fiber-Elastomer Composites

The preparation of intelligent structures for multiple smart applications such as soft-robotics, artificial limbs, etc., is a rapidly evolving research topic. In the present work, the preparation of a functional fabric, and its integration into a soft elastomeric matrix to develop an adaptive fiber-elastomer composite structure, is presented. Functional fabric, with the implementation of the shape memory effect, was combined with liquid polybutadiene rubber by means of a low-temperature vulcanization process. A detailed investigation on the crosslinking behavior of liquid polybutadiene rubber was performed to develop a rubber formulation that is capable of crosslinking liquid rubber at 75 °C, a temperature that is much lower than the phase transformation temperature of SMA wires (90-110 °C). By utilizing the unique low-temperature crosslinking protocol for liquid polybutadiene rubber, soft intelligent structures containing functional fabric were developed. The adaptive structures were successfully activated by Joule heating. The deformation behavior of the smart structures was experimentally demonstrated by reaching a 120 mm bending distance at an activation voltage of 8 V without an additional load, whereas 90 mm, 70 mm, 65 mm, 57 mm bending distances were achieved with attached weights of 5 g, 10 g, 20 g, 30 g, respectively.

Processing of Self-Healing Polymers for Soft Robotics

Soft robots are, due to their softness, inherently safe and adapt well to unstructured environments. However, they are prone to various damage types. Self-healing polymers address this vulnerability. Self-healing soft robots can recover completely from macroscopic damage, extending their lifetime. For developing healable soft robots, various formative and additive manufacturing methods have been exploited to shape self-healing polymers into complex structures. Additionally, several novel manufacturing techniques, noted as (re)assembly binding techniques that are specific to self-healing polymers, have been created. Herein, the wide variety of processing techniques of self-healing polymers for robotics available in the literature is reviewed, and limitations and opportunities discussed thoroughly. Based on defined requirements for soft robots, these techniques are critically compared and validated. A strong focus is drawn to the reversible covalent and (physico)chemical cross-links present in the self-healing polymers that do not only endow healability to the resulting soft robotic components, but are also beneficial in many manufacturing techniques. They solve current obstacles in soft robots, including the formation of robust multi-material parts, recyclability, and stress relaxation. This review bridges two promising research fields, and guides the reader toward selecting a suitable processing method based on a self-healing polymer and the intended soft robotics application.

Magnetic materials: a journey from finding north to an exciting printed future

The potential implications/applications of printing technologies are being recognized worldwide across different disciplines and industries. Printed magnetoactive smart materials, whose physical properties can be changed by the application of external magnetic fields, are an exclusive class of smart materials that are highly valuable due to their magnetically activated smart and/or multifunctional response. Such smart behavior allows, among others, high speed and low-cost wireless activation, fast response, and high controllability with no relevant limitations in design, shape, or dimensions. Nevertheless, the printing of magnetoactive materials is still in its infancy, and the design apparatus, the material set, and the fabrication procedures are far from their optimum features. Thus, this review presents the main concepts that allow interconnecting printing technologies with magnetoactive materials by discussing the advantages and disadvantages of this joint field, trying to highlight the scientific obstacles that still limit a wider application of these materials nowadays. Additionally, it discusses how these limitations could be overcome, together with an outlook of the remaining challenges in the emerging digitalization, Internet of Things, and Industry 4.0 paradigms. Finally, as magnetoactive materials will play a leading role in energy generation and management, the magnetic-based Green Deal is also addressed.

Enzymatic and Chemical Approaches for Post-Polymerization Modifications of Diene Rubbers: Current state and Perspectives

Diene rubbers are polymeric materials which present elastic properties and have double bonds in the macromolecular backbone after the polymerization process. Post-polymerization modifications of rubbers can be conducted by enzymatic or chemical methods. Enzymes are environmentally friendly catalysts and with the increasing demand for rubber waste management, biodegradation and biomodifications have become hot topics of research. Some rubbers are renewable materials and are a source of organic molecules, and biodegradation can be conducted to obtain either oligomers or monomers. On the other hand, chemical modifications of rubbers by click-chemistry are important strategies for the creation and combination of new materials. In a way to expand the scope of uses to other non-traditional applications, several and effective modifications can be conducted with diene rubbers. Two groups of efficient tools, enzymatic, and chemical modifications in diene rubbers, are summarized in this review. By analyzing stereochemical and reactivity aspects, the authors also point to some applications perspectives for biodegradation products and to rational modifications of diene rubbers by combining both methodologies.