Controlling frontal photopolymerization with optical attenuation and mass diffusion

Frontal Polymerizations: From Chemical Perspectives to Macroscopic Properties and Applications

The synthesis and processing of most thermoplastics and thermoset polymeric materials rely on energy-inefficient and environmentally burdensome manufacturing methods. Frontal polymerization is an attractive, scalable alternative due to its exploitation of polymerization heat that is generally wasted and unutilized. The only external energy needed for frontal polymerization is an initial thermal (or photo) stimulus that locally ignites the reaction. The subsequent reaction exothermicity provides local heating; the transport of this thermal energy to neighboring monomers in either a liquid or gel-like state results in a self-perpetuating reaction zone that provides fully cured thermosets and thermoplastics. Propagation of this polymerization front continues through the unreacted monomer media until either all reactants are consumed or sufficient heat loss stalls further reaction. Several different polymerization mechanisms support frontal processes, including free-radical, cat- or anionic, amine-cure epoxides, and ring-opening metathesis polymerization. The choice of monomer, initiator/catalyst, and additives dictates how fast the polymer front traverses the reactant medium, as well as the maximum temperature achievable. Numerous applications of frontally generated materials exist, ranging from porous substrate reinforcement to fabrication of patterned composites. In this review, we examine in detail the physical and chemical phenomena that govern frontal polymerization, as well as outline the existing applications.

Micropatterns Fabricated by Photodimerization-Induced Diffusion

Pattern technology plays an important role in the generation of microstructures with different functionalities and morphologies. In this report, a straightforward and versatile strategy is presented for spatially regulating the growth of a microstructure on a surface by the photodimerization of maleimide (MI). Upon exposure of ultraviolet (UV) light, photodimerization of MI in a film comprising furan-grafted polymer and bismaleimide (BMI) produces a chemical gradient, which can drive the diffusion of BMI from the unexposed to the exposed region and from the bottom to the surface, resulting in the growth of micropatterns. Sequential crosslinking induced by the Diels-Alder reaction between MI and furan maintains the stability of pattern shape. Theoretical modeling with reaction-diffusion equations reveal that as photodimerization moves the system far from thermodynamic equilibrium, the formation of a chemical potential gradient requires the redistribution of matter, resulting in the formation of topographies. Directional molecular motion induced by UV light can generate complex morphology, and produce materials with unique optical functions, such as charming-ordered gratings. This straightforward method of fabricating micropatterns by photodimerization-induced diffusion is successfully applied to patterned curved surfaces, microfluidic channels and encapsulation of integrated light emitting diode chips.

Photoinitiating systems and kinetics of frontal photopolymerization processes – the prospects for efficient preparation of composites and thick 3D structures

The frontal photopolymerisation combining a versatile interest in many applications and economic efficiency is destined to occupy a growing polymer economy.

Spatiotemporally Controlled Photoresponsive Hydrogels: Design and Predictive Modeling from Processing through Application

Photoresponsive hydrogels (PRHs) are soft materials whose mechanical and chemical properties can be tuned spatially and temporally with relative ease. Both photo-crosslinkable and photodegradable hydrogels find utility in a range of biomedical applications that require tissue-like properties or programmable responses. Progress in engineering with PRHs is facilitated by the development of theoretical tools that enable optimization of their photochemistry, polymer matrices, nanofillers, and architecture. This review brings together models and design principles that enable key applications of PRHs in tissue engineering, drug delivery, and soft robotics, and highlights ongoing challenges in both modeling and application.

Thermal control of SZ2080 photopolymerization in four-beam interference lithography

Photopolymerization by four-beam interference lithography on a preheated SZ2080 sample was explored at different initial temperatures of the sample: 20 °C, 50 °C, 75 °C, 100 °C, 125 °C, and 150 °C, and at exposure times ranging from 0.5 s to 5 s. The average laser power selected was ∼100 mW for the 300 ps duration pulses at a 1 kHz repetition rate. The experimental results demonstrate that the higher initial temperature of the sample positively influences the crosslinking of the patterns. These findings will improve polymerization protocols for multi-beam interference lithography.

Monomer diffusion into static and evolving polymer networks during frontal photopolymerisation

Frontal photopolymerisation (FPP) is a directional solidification process that converts monomer-rich liquid into crosslinked polymer solid by light exposure and finds applications ranging from lithography to 3D printing. Inherent to this process is the creation of an evolving polymer network that is exposed to a monomer bath. A combined theoretical and experimental investigation is performed to determine the conditions under which monomer from this bath can diffuse into the propagating polymer network and cause it to swell. First, the growth and swelling processes are decoupled by immersing pre-made polymer networks into monomer baths held at various temperatures. The experimental measurements of the network thickness are found to be in good agreement with theoretical predictions obtained from a nonlinear poroelastic model. FPP propagation experiments are then carried out under conditions that lead to swelling. Unexpectedly, for a fixed exposure time, swelling is found to increase with incident light intensity. The experimental data is well described by a novel FPP model accounting for mass transport and the mechanical response of the polymer network, providing key insights into how monomer diffusion affects the conversion profile of the polymer solid and the stresses that are generated during its growth. The predictive capability of the model will enable the fabrication of gradient materials with tuned mechanical properties and controlled stress development.

Frontal Conversion and Uniformity in 3D Printing by Photopolymerisation

We investigate the impact of the non-uniform spatio-temporal conversion, intrinsic to photopolymerisation, in the context of light-driven 3D printing of polymers. The polymerisation kinetics of a series of model acrylate and thiol-ene systems, both neat and doped with a light-absorbing dye, is investigated experimentally and analysed according to a descriptive coarse-grained model for photopolymerisation. In particular, we focus on the relative kinetics of polymerisation with those of 3D printing, by comparing the evolution of the position of the conversion profile (z_f) to the sequential displacement of the object stage (∆z). After quantifying the characteristic sigmoidal monomer-to-polymer conversion of the various systems, with a combination of patterning experiments, FT-IR mapping, and modelling, we compute representative regimes for which z_f is smaller, commensurate with, or larger than ∆z. While non-monotonic conversion can be detrimental to 3D printing, for instance in causing differential shrinkage of inhomogeneity in material properties, we identify opportunities for facile fabrication of modulated materials in the z-direction (i.e., along the illuminated axis). Our simple framework and model, based on directly measured parameters, can thus be employed in photopolymerisation-based 3D printing, both in process optimisation and in the precise design of complex, internally stratified materials by coupling the z-stage displacement and frontal polymerisation kinetics.

A Unified Approach for Patterning via Frontal Photopolymerization

A unified patterning strategy via frontal photopolymerization (FPP) that is robust to a wide range of radical photopolymerizing systems, including thiol-ene and acrylic monomers is reported. The factors governing the spatiotemporal solidification process, including front position, profile shape, and thermal effects, are investigated and modeled theoretically, resulting in the predictive FPP patterning of polymer networks with prescribed dimensions.

Role of heat generation and thermal diffusion during frontal photopolymerization

Frontal photopolymerization (FPP) is a rapid and versatile solidification process that can be used to fabricate complex three-dimensional structures by selectively exposing a photosensitive monomer-rich bath to light. A characteristic feature of FPP is the appearance of a sharp polymerization front that propagates into the bath as a planar traveling wave. In this paper, we introduce a theoretical model to determine how heat generation during photopolymerization influences the kinetics of wave propagation as well as the monomer-to-polymer conversion profile, both of which are relevant for FPP applications and experimentally measurable. When thermal diffusion is sufficiently fast relative to the rate of polymerization, the system evolves as if it were isothermal. However, when thermal diffusion is slow, a thermal wavefront develops and propagates at the same rate as the polymerization front. This leads to an accumulation of heat behind the polymerization front which can result in a significant sharpening of the conversion profile and acceleration of the growth of the solid. Our results also suggest that a novel way to tailor the dynamics of FPP is by imposing a temperature gradient along the growth direction.