Design and Synthesis of Free-Radical/Cationic Photosensitive Resin Applied for 3D Printer with Liquid Crystal Display (LCD) Irradiation

Characteristics of pollutant generation from 3D-printed photocured waste combustion

With the rapid advancement of photopolymerization-based 3D printing technology, the volume of PCW has experienced a sharp increase. The potential environmental ramifications of PCW disposal demand careful consideration, especially given its current practice of being incineration alongside MSW. In this study, the TG-MS/FTIR system was carried out to probe the thermogravimetric characteristics and volatile byproducts during combustion. Various product compositions resulting from different mixing ratios of PCW incineration with MSW were investigated. It was observed that fluorene (C13H10) and triphenylene (C18H12) produced by PCW combustion 0.52 mg/g and 0.43 mg/g respectively, which are twice as abundant as those generated from normal plastic. When PCW incineration along with MSW, compounds such as naphthalene (C10H8), cyclohexane (C6H12), and heptane (C7H16) were generated in concentrations of 1.25 mg/g, 1.05 mg/g, and 0.95 mg/g respectively, which are at least twice as much as with MSW incineration alone. The incineration of PCW with rubber and textiles resulted in the production of 2.34 mg/g to 3.76 mg/g more PAHs compared to PCW combustion alone. The incineration of PCW with paper resulted in the production of 3.12 mg/g to 5.15 mg/g more heptane, nonane, cyclohexane, pyrene, and anthracene than PCW combustion alone. Incineration of PCW with wood proved to be the cleanest method, with product contents primarily below 0.10 mg/g. When incinerated with food residues or normal plastic, most of the product content remained below 0.05 mg/g. Considering the environmental pollution resulting from PCW combustion, the disposal of PCW warrants careful consideration and management.

A 4D-Printable Photocurable Resin Derived from Waste Cooking Oil with Enhanced Tensile Strength

In pursuit of enhancing the mechanical properties, especially the tensile strength, of 4D-printable consumables derived from waste cooking oil (WCO), we initiated the production of acrylate-modified WCO, which encompasses epoxy waste oil methacrylate (EWOMA) and epoxy waste oil acrylate (EWOA). Subsequently, a series of WCO-based 4D-printable photocurable resins were obtained by introducing a suitable diacrylate molecule as the second monomer, coupled with a composite photoinitiator system comprising Irgacure 819 and p-dimethylaminobenzaldehyde (DMAB). These materials were amenable to molding using an LCD light-curing 3D printer. Our findings underscored the pivotal role of triethylene glycol dimethacrylate (TEGDMA) among the array of diacrylate molecules in enhancing the mechanical properties of WCO-based 4D-printable resins. Notably, the 4D-printable material, composed of EWOA and TEGDMA in an equal mass ratio, exhibited nice mechanical strength comparable to that of mainstream petroleum-based 4D-printable materials, boasting a tensile strength of 9.17 MPa and an elongation at break of 15.39%. These figures significantly outperformed the mechanical characteristics of pure EWOA or TEGDMA resins. Furthermore, the EWOA-TEGDMA resin demonstrated impressive thermally induced shape memory performance, enabling deformation and recovery at room temperature and retaining its shape at -60 °C. This resin also demonstrated favorable biodegradability, with an 8.34% weight loss after 45 days of soil degradation. As a result, this 4D-printable photocurable resin derived from WCO holds immense potential for the creation of a wide spectrum of high-performance intelligent devices, brackets, mold, folding structures, and personalized products.

Photopolymerization of Limonene Dioxide and Vegetable Oils as Biobased 3D-Printing Stereolithographic Formulation

Epoxidized vegetable oils and limonene dioxide, a bis-epoxide derived from the terpene limonene, are photo-copolymerized to yield highly crosslinked networks with high conversion of all epoxide groups at ambient temperature. However, the slow polymerization of such biobased formulation polymerizes is not compatible for a use in a commercial SLA 3D printer. Adding an acrylated epoxidized vegetable oil to the bis-epoxide leads to a decrease of curing time and an increase in LDO conversion to polymer. For example, in a 60:40 wt:wt mixture of LDO and epoxidized soybean oil, the conversions of both exocyclic and endocyclic epoxide groups of LDO are ≥95%. These formulations were successfully used in SLA 3D printers, leading to generation of hard and dry complex objects using biobased formulations.

Fabrication and properties of PLA/β-TCP scaffolds using liquid crystal display (LCD) photocuring 3D printing for bone tissue engineering

Introduction: Bone defects remain a thorny challenge that clinicians have to face. At present, scaffolds prepared by 3D printing are increasingly used in the field of bone tissue repair. Polylactic acid (PLA) has good thermoplasticity, processability, biocompatibility, and biodegradability, but the PLA is brittle and has poor osteogenic performance. Beta-tricalcium phosphate (β-TCP) has good mechanical properties and osteogenic induction properties, which can make up for the drawbacks of PLA. Methods: In this study, photocurable biodegradable polylactic acid (bio-PLA) was utilized as the raw material to prepare PLA/β-TCP slurries with varying β-TCP contents (β-TCP dosage at 0%, 10%, 20%, 30%, 35% of the PLA dosage, respectively). The PLA/β-TCP scaffolds were fabricated using liquid crystal display (LCD) light-curing 3D printing technology. The characterization of the scaffolds was assessed, and the biological activity of the scaffold with the optimal compressive strength was evaluated. The biocompatibility of the scaffold was assessed through CCK-8 assays, hemocompatibility assay and live-dead staining experiments. The osteogenic differentiation capacity of the scaffold on MC3T3-E1 cells was evaluated through alizarin red staining, alkaline phosphatase (ALP) detection, immunofluorescence experiments, and RT-qPCR assays. Results: The prepared scaffold possesses a three-dimensional network structure, and with an increase in the quantity of β-TCP, more β-TCP particles adhere to the scaffold surface. The compressive strength of PLA/β-TCP scaffolds exhibits a trend of initial increase followed by decrease with an increasing amount of β-TCP, reaching a maximum value of 52.1 MPa at a 10% β-TCP content. Degradation rate curve results indicate that with the passage of time, the degradation rate of the scaffold gradually increases, and the pH of the scaffold during degradation shows an alkaline tendency. Additionally, Live/dead staining and blood compatibility experiments suggest that the prepared PLA/β-TCP scaffold demonstrates excellent biocompatibility. CCK-8 experiments indicate that the PLA/β-TCP group promotes cell proliferation, and the prepared PLA/β-TCP scaffold exhibits a significant ability to enhance the osteogenic differentiation of MC3T3-E1 cells in vitro. Discussion: 3D printed LCD photocuring PLA/β-TCP scaffolds could improve surface bioactivity and lead to better osteogenesis, which may provide a unique strategy for developing bioactive implants in orthopedic applications.

Epoxy-Based Blend Formulation for Dual Curing in Liquid Crystal Display 3D Printing: A Study on Thermomechanical Properties Variation for Enhanced Printability

The aim of this study was to explore the thermal properties of epoxy-acrylate blends for the liquid crystal display (LCD) 3D printing technique. Starting from an epoxy-acrylate blend with a ratio of epoxy to acrylate of 50:50, the effect of adding a reactive monofunctional epoxy diluent was evaluated. The diluent was a resin composed by oxirane, mono[(C12-14 alkyl) methyl] derivatives selected for its low viscosity (i.e., 1.8 Poise) at room temperature and its reactivity. The diluent content varied from 15 to 25 wt% and, for all the formulation, double curing cycles, where thermal curing followed photocuring, were studied. The effect of different curing temperatures was also evaluated. The control of the diluent content and of the curing temperature allowed tailoring of the thermomechanical resin properties while improving the resin's processability. The glass transition ranged from 115.4 °C to 90.8 °C depending on the combination of diluent content and post-curing temperature. The resin developed displayed a faster processing time tested on a reference part with printing time of 4 h and 20 min that was much lower than the printing times (7 and 16 h) observed for the starting formulations.

Electrohydrodynamic printing of submicron-microscale hybrid scaffolds with improved cellular adhesion and proliferation behaviors

Electrohydrodynamic (EHD) printing has been considered as a mature strategy to mimic the hierarchical microarchitectures in native extracellular matrix (ECM). Most of the EHD-printed scaffolds possess single-dimensional fibrous structures, which cannot mimic the multi-dimensional architectures for enhanced cellular behaviors. Here we developed a two-nozzle EHD printing system to fabricate hybrid scaffolds involving submicron and microscale features. The polyethylene oxide- polycaprolactone (PEO-PCL) submicron fibers were fabricated via solution-based EHD printing with a width of 527 ± 56 nm. The PCL microscale fibers were fabricated via melt-based EHD printing with a width of 11.2 ± 2.3μm. The hybrid scaffolds were fabricated by printing the submicron and microscale fibers in a layer-by-layer manner. The microscale scaffolds were utilized as a control group. Rat myocardial cells (H9C2 cells) were cultured on the two kinds of scaffolds for the culturing period of 1, 3 and 5 d. Biological results indicated that H9C2 cells showed enhanced adhesion and proliferation behaviors on the hybrid scaffold than those on the pure microscale scaffold. This work offers a facile and scalable strategy to fabricate multiscale synthetic scaffolds, which might be further explored to regulate cellular behaviors in the fields of tissue regeneration and biomedical engineering.

3D printing of bone and cartilage with polymer materials

Damage and degeneration to bone and articular cartilage are the leading causes of musculoskeletal disability. Commonly used clinical and surgical methods include autologous/allogeneic bone and cartilage transplantation, vascularized bone transplantation, autologous chondrocyte implantation, mosaicplasty, and joint replacement. 3D bio printing technology to construct implants by layer-by-layer printing of biological materials, living cells, and other biologically active substances in vitro, which is expected to replace the repair mentioned above methods. Researchers use cells and biomedical materials as discrete materials. 3D bio printing has largely solved the problem of insufficient organ donors with the ability to prepare different organs and tissue structures. This paper mainly discusses the application of polymer materials, bio printing cell selection, and its application in bone and cartilage repair.

A novel technology for preparing the placebos of vortioxetine hydrobromide tablets using LCD 3D printing

This study aimed to describe the use of liquid crystal display (LCD) three-dimensional (3D) printing technology to prepare moulds for vortioxetine hydrobromide (VOR) tablet placebos and provide an economical, convenient, and flexible method for the small-batch preparation of special-shaped, scored, and coated placebo tablets. First, LCD 3D printing was used to generate different placebo moulds of VOR tablets based on VOR tablet digital models subtracted from the digital models of cuboid moulds by Boolean operation to optimise the structures of moulds. The better placebo mould had a parting surface located at the 7/10 height of the packing cavities and the positioning columns and slots were three pairs, and the efflux space had slender efflux channels combined with wide efflux tanks. Next, the placebo mould was corrected by the dimensional compensation method due to the shrinkage rates of the packing cavities (2.42%) and placebo prescription (1.12%) and the thickness of the film coating (25.08 μm). The placebo prescription was 8% hydroxypropyl methylcellulose (SH K15M) hydroalcoholic gel, and its mass ratio to lactose was 0.8:2. The placebos were coated with 13% gastric-soluble film coating solution for 30 min and polished with the 30% PEG 4000 solution. The National Bureau of Standards value between the VOR tablets and their placebos was 1.22 ± 0.10 (less than1.5). Finally, the mass of the placebos was similar to that of the VOR tablets. Their dimensional differences were less than 0.1 mm. Their mass, colour, odour, shape, and texture were all similar, which were assessed by manual evaluation. In conclusion, the preparations of VOR tablet placebos can be applied in placebo-controlled trials, and LCD 3D printing has an extensive application value in preparing placebo tablets.

Pyrolysis properties and kinetics of photocured waste from photopolymerization-based 3D printing: A TG-FTIR/GC-MS study

The emerging photopolymerization-based 3D printing industry has led to a growing concern for the disposal of photocured waste (PCW), which is inevitably generated during the life cycle of photopolymerization-based 3D printing. In order to shed light on suitable thermochemical treatment and utilization approaches of PCW, this work comprehensively investigated the properties and kinetics during PCW pyrolysis via TG-FTIR/GC-MS analysis. The results demonstrated that the main decomposition of PCW sample happened in the range 320-550 °C with a total weight loss of 93.34 wt%. According to the result of four kinetic models, the activation energy of PCW sample was approximately 228.58-245.05 kJ/mol. Finally, the FTIR and GC-MS results manifested that the main components of volatiles released at different heating rates were the same. The volatiles mainly include (S)-(+)-2-hydroxy-2-phenylprop, benzaldehyde, benzophenone (photo-initiator), benzoic acid, benzoylformic acid etc., which have a multitude of potential applications. However, these volatiles produced by PCW pyrolysis have a certain toxicity and potential hazard. This study demonstrates insightful fundamentals for thermochemical disposal of PCW, which appears to be potentially valuable with the rapid development of the photopolymerization-based 3D printing industry.

Synthesis and Optimization of a Free-Radical/Cationic Hybrid Photosensitive UV Curable Resin Using Polyurethane Acrylate and Graphene Oxide

Cost-effective, practical, and efficiently performing photosensitive resin composite materials are essential, as the current materials are expensive, lack better alternatives, and do not meet 3D printing standards. In this study, based on orthogonal experiments for photosensitive resin curing, we prepared a free-radical/cationic hybrid photosensitive UV cured resin (UVR) using acrylic ester and epoxy resin as the prepolymers, tripropylenediol diacrylate (TPGDA) as the active diluent, and triaryl sulfonium salt (I-160) and 2,2-dimethyl-α-hydroxy acetophenone (1173) as the photoinitiators, in the optimized formula of acrylic-ester:epoxy-resin:TPGDA:I-160:1173 = 37.5:37.5:20:2.5:2.5. Further, we investigated the effects of polyurethane acrylates (PUA) and Graphene oxide (GO) on the surface morphology, chemical structure, hydrophobicity, mechanical strength, and gelation rate of the hybrid resin. We observed that 20% PUA improved tensile strength to the maximum of 36.89 MPa from 16.42 MPa of the unmodified hybrid resin, whereas 1% GO reduced volume shrinkage to the minimum of 2.89% from 3.73% of the unmodified hybrid resin. These photosensitive resins with higher tensile strength and lower volume shrinkage can be used to synthesize high performance functional materials in the future.

Nano-Hydroxyapatite Bone Scaffolds with Different Porous Structures Processed by Digital Light Processing 3D Printing

The morphologies and structures of the scaffold have a significant influence on their mechanical and biological properties. In this work, different types of porous structures: Triply periodic minimal surface-Schwarz primitive (P), body-centered cubic, and cubic pore-shaped (CPS) hydroxyapatite scaffolds with ~70% porosity were fabricated through digital light processing (DLP) 3D printing technology. The compressive properties and in vitro cell evaluations such as cell proliferation and attachment morphology of these scaffolds were systematically compared. The results showed that the CPS scaffolds exhibited the highest compressive strength (~22.5 MPa) and modulus (~400 MPa). In addition, the CPS scaffolds also performed the most active cell metabolisms as compared to other two structures, which may account for the larger pore size and smaller curvature of the substrate. This study provides a general guidance for the fabrication and selection of porous bone scaffolds processed by DLP 3D printing.

Mechanical Properties and Biocompatibility of Urethane Acrylate-Based 3D-Printed Denture Base Resin

In this study, five urethane acrylates (UAs), namely aliphatic urethane hexa-acrylate (87A), aromatic urethane hexa-acrylate (88A), aliphatic UA (588), aliphatic urethane triacrylate diluted in 15% HDD (594), and high-functional aliphatic UA (5812), were selected to formulate five UA-based photopolymer resins for digital light processing (DLP)-based 3D printing. Each UA (40 wt%) was added and blended homogenously with ethoxylated pentaerythritol tetraacrylate (40 wt%), isobornyl acrylate (12 wt%), diphenyl (2,4,6-trimethylbenzoyl) phosphine oxide (3 wt%), and a pink acrylic (5 wt%). Each UA-based resin specimen was designed using CAD software and fabricated using a DLP 3D printer to specific dimensions. Characteristics, mechanical properties, and cytotoxicity levels of these designed UA-based resins were investigated and compared with a commercial 3D printing denture base acrylic resin (BB base) control group at different UV exposure times. Shore hardness-measurement data and MTT assays were analyzed using a one-way analysis of variance with Bonferroni's post hoc test, whereas viscosity, maximum strength, and modulus were analyzed using the Kruskal-Wallis test (α = 0.05). UA-based photopolymer resins with tunable mechanical properties were successfully prepared by replacing the UA materials and the UV exposure times. After 15 min of UV exposure, the 5812 and 594 groups exhibited higher viscosities, whereas the 88A and 87A groups exhibited lower viscosities compared with the BB base group. Maximum flexural strength, flexural modulus, and Shore hardness values also revealed significant differences among materials (p < 0.001). Based on MTT assay results, the UA-based photopolymer resins were nontoxic. In the present study, mechanical properties of the designed photopolymer resins could be adjusted by changing the UA or UV exposure time, suggesting that aliphatic urethane acrylate has good potential for use in the design of printable resins for DLP-type 3D printing in dental applications.