High-throughput microscopy to determine morphology, microrheology, and phase boundaries applied to phase separating coacervates

Continuous Polymer Synthesis and Manufacturing of Polyurethane Elastomers Enabled by Automation

Connecting polymer synthesis and processing is an important challenge for streamlining the manufacturing of polymeric materials. In this work, the automated synthesis of acrylate-capped polyurethane oligomers is integrated with vat photopolymerization 3D printing. This strategy enabled the rapid manufacturing of a library of polyurethane-based elastomeric materials with differentiated thermal and mechanical properties. The automated semicontinuous batch synthesis approach proved enabling for resins with otherwise short shelf lives because of the intimate connection between synthesis, formulation, and processing. Structure-property studies demonstrated the ability to tune properties through systematic alteration of cross-link density and chemical composition.

Navigating the Expansive Landscapes of Soft Materials: A User Guide for High-Throughput Workflows

Synthetic polymers are highly customizable with tailored structures and functionality, yet this versatility generates challenges in the design of advanced materials due to the size and complexity of the design space. Thus, exploration and optimization of polymer properties using combinatorial libraries has become increasingly common, which requires careful selection of synthetic strategies, characterization techniques, and rapid processing workflows to obtain fundamental principles from these large data sets. Herein, we provide guidelines for strategic design of macromolecule libraries and workflows to efficiently navigate these high-dimensional design spaces. We describe synthetic methods for multiple library sizes and structures as well as characterization methods to rapidly generate data sets, including tools that can be adapted from biological workflows. We further highlight relevant insights from statistics and machine learning to aid in data featurization, representation, and analysis. This Perspective acts as a "user guide" for researchers interested in leveraging high-throughput screening toward the design of multifunctional polymers and predictive modeling of structure-property relationships in soft materials.

Amphiphilic monomers bridge hydrophobic polymers and water

Water dissolves a hydrophilic polymer, but not a hydrophobic polymer. Many monomers of hydrophilic polymers, however, are amphiphilic, with a hydrophobic vinyl group for radical polymerization, as well as a hydrophilic group. Consequently, such an amphiphilic monomer may form solutions with both water and hydrophobic polymers. Ternary mixtures of amphiphilic monomer, hydrophobic polymer, and water have recently been used as precursors for interpenetrating polymer networks of hydrophilic polymers and hydrophobic polymers of unusual properties. However, the phase behavior of the ternary mixtures of amphiphilic monomer, hydrophobic polymer, and water themselves has not been studied. Here we mix the amphiphilic monomer acrylic acid, the hydrophobic polymer poly(methyl methacrylate), and water. In the mixture, the hydrophobic polymer can form various morphologies, including solution, micelle, gel, and polymer glass. We interpret these findings by invoking that the hydrophobic and hydrophilic groups of the amphiphilic monomer enable it to function as a bridge. That is, the hydrophobic functional group binds with the hydrophobic polymer, and the hydrophilic functional group binds with water. This picture leads to a simple modification to the Flory-Huggins theory, which agrees well with our experimental data. Amphiphilic monomers offer a rich area for further study for scientific insight, as well as for expanding opportunities to develop materials of self-assembled structures with unusual properties.

Coacervate or precipitate? Formation of non-equilibrium microstructures in coacervate emulsions

Non-equilibrium processing of aqueous polyelectrolyte complex (PEC) coacervates is critical to many applications. In particular, many coacervate-forming systems are known to become trapped in out-of-equilibrium states (e.g., precipitation). The mechanism and conditions under which these states form, and whether they age, is not clearly understood. Here, we elucidate the influence of processing on the PEC coarsening mechanism as it varies with flow during mixing for a model system of poly(allylamine hydrochloride) and poly(acrylic acid sodium salt) in water. We demonstrate that flow conditions can be used to toggle the formation of rough, precipitate-like aggregates of micron-scale PEC structures. These structures form at compositions with viscous-dominant equilibrium rheology, and observations of their formation via optical microscopy suggest that they comprise colloidal aggregates of PEC coacervate droplets. We further show that these aggregates exhibit micron-scale coarsening, with a mixing time-dependent characteristic aging time scale. The results show that the formation of precipitate-like structures is not solely determined by composition, but is instead highly sensitive to mass transport and colloidal instability effects. Our observations suggest that the details of mixing flow can provide non-equilibrium structural control of a broad range of PEC coacervate materials orthogonally to structure-property inspired polymeric design. We anticipate that these findings will open the door for future studies on the control of non-equilibrium PEC formation and structure.

Competition between β-Sheet and Coacervate Domains Yields Diverse Morphologies in Mixtures of Oppositely Charged Homochiral Polypeptides

Biomolecular assembly processes involving competition between specific intermolecular interactions and thermodynamic phase instability have been implicated in a number of pathological states and technological applications of biomaterials. As a model for such processes, aqueous mixtures of oppositely charged homochiral polypeptides such as poly-l-lysine and poly-l-glutamic acid have been reported to form either β-sheet-rich solid-like precipitates or liquid-like coacervate droplets depending on competing hydrogen bonding interactions. Herein, we report studies of polypeptide mixtures that reveal unexpectedly diverse morphologies ranging from partially coalescing and aggregated droplets to bulk precipitates, as well as a previously unreported re-entrant liquid-liquid phase separation at high polypeptide concentration and ionic strength. Combining our experimental results with all-atom molecular dynamics simulations of folded polypeptide complexes reveals a concentration dependence of β-sheet-rich secondary structure, whose relative composition correlates with the observed macroscale morphologies of the mixtures. These results elucidate a crucial balance of interactions that are important for controlling morphology during coacervation in these and potentially similar biologically relevant systems.

Emulsion imaging of a DNA nanostar condensate phase diagram reveals valence and electrostatic effects

Liquid-liquid phase separation (LLPS) in macromolecular solutions (e.g., coacervation) is relevant both to technology and to the process of mesoscale structure formation in cells. The LLPS process is characterized by a phase diagram, i.e., binodal lines in the temperature/concentration plane, which must be quantified to predict the system's behavior. Experimentally, this can be difficult due to complications in handling the dense macromolecular phase. Here, we develop a method for accurately quantifying the phase diagram without direct handling: We confine the sample within micron-scale, water-in-oil emulsion droplets and then use precision fluorescent imaging to measure the volume fraction of the condensate within the droplet. We find that this volume fraction grows linearly with macromolecule concentration; thus, by applying the lever rule, we can directly extract the dense and dilute binodal concentrations. We use this approach to study a model LLPS system of self-assembled, fixed-valence DNA particles termed nanostars (NSs). We find that temperature/concentration phase diagrams of NSs display, with certain exceptions, a larger co-existence regime upon increasing salt or valence, in line with expectations. Aspects of the measured phase behavior validate recent predictions that account for the role of valence in modulating the connectivity of the condensed phase. Generally, our results on NS phase diagrams give fundamental insight into limited-valence phase separation, while the method we have developed will likely be useful in the study of other LLPS systems.