Wavelength Selective Multi-Material 3D Printing of Soft Active Devices Using Orthogonal Photoreactions.

Orthogonal photoreactions provide a unique way to locally and independently control (thermo)mechanical properties and functionality of polymer networks simply by choice of the wavelength. Herein, a library of acrylate functional coumarin monomers is synthesized, which are cured by sequence-dependent wavelength orthogonality. In the presence of a long wavelength absorbing photoinitiator, the monomers undergo rapid curing by visible light induced radical chain growth polymerization. Subsequent irradiation with light in the UV-A region selectively initiates the [2+2] photocycloaddition of the coumarin chromophores, which is confirmed by FTIR and UV-vis experiments. Through a well-targeted design, acrylate-based and thiol-acrylate resin formulations are prepared, whose fast curing rate, low viscosity, and prolonged storage stability enable the one-step fabrication of multi-material structures by digital light processing (DLP) 3D printing. By using a dual-wavelength printer, which operates at two different wavelengths (405 and 365 nm), objects comprising soft (ε = 22%, σ = 7.5 MPa) and stiff (ε = 2%, σ = 8.3 MPa) domains are printed with a single resin vat. Along with tensile properties, the wavelength selective change in the network structure features a local control of the glass transition temperature (ΔTg  = 17 °C) in the 3D-printed objects. Soft active devices are fabricated by dual-wavelength DLP 3D printing, with distinct domains having a higher Tg and the local programming of multi shapes is demonstrated.

On-Demand Activation of Transesterification by Chemical Amplification in Dynamic Thiol-Ene Photopolymers.

Chemical amplification is a well-established concept in photoresist technology, wherein one photochemical event leads to a cascade of follow-up reactions that facilitate a controlled change in the solubility of a polymer. Herein, we transfer this concept to dynamic polymer networks to liberate both catalyst and functional groups required for bond exchange reactions under UV irradiation. For this, we exploit a photochemically generated acid to catalyse a deprotection reaction of an acid-labile tert-butoxycarbonyl group, which is employed to mask the hydroxy groups of a vinyl monomer. At the same time, the released acid serves as a catalyst for thermo-activated transesterifications between the deprotected hydroxy and ester moieties. Introduced in an orthogonally cured (450 nm) thiol-click photopolymer, this approach allows for a spatio-temporally controlled activation of bond exchange reactions, which is crucial in light of the creep resistance versus reflow ability trade-off of dynamic polymer networks.

Introduction of Photolatent Bases for Locally Controlling Dynamic Exchange Reactions in Thermo-Activated Vitrimers.

Vitrimers exhibit a covalently crosslinked network structure, as is characteristic of classic thermosetting polymers. However, they are capable of rearranging their network topology by thermo-activated associative exchange reactions when the topology freezing transition temperature (Tv ) is exceeded. Despite the vast number of developed vitrimers, there is a serious lack of methods that enable a (spatially) controlled onset of these rearrangement reactions above Tv . Herein, we highlight the localized release of the efficient transesterification catalyst 1,5,7-triazabicyclo[4.4.0]dec-5-ene (TBD) by the UV-induced cleavage of a photolatent base within a covalently crosslinked thiol-epoxy network. Demonstrated with stress relaxation measurements conducted well above the network's Tv , only the controlled release of TBD facilitates the immediate onset of transesterification in terms of a viscoelastic flow. Moreover, the spatially resolved UV-mediated photoactivation of vitrimeric properties is confirmed by permanent shape changes induced locally in the material.

Laser-Triggered Writing and Biofunctionalization of Thiol-Ene Networks.

The light responsivity of ortho-nitrobenzyl esters (o-NBE) is exploited to inscribe µ-scale 2.5D patterns in thiol-ene networks by direct laser writing. For this purpose, a multifunctional thiol and a photosensitive alkene with an o-NBE chromophore are cured upon visible light exposure without inducing a premature photocleavage of the o-NBE links. Once the network is formed, a laser beam source with a wavelength of 375 nm is used for selectively inducing the photocleavage reaction of the o-NBE groups. Positive tone patterns are directly inscribed onto the sample surface without the requirement of a subsequent development step (removing soluble species in an appropriate organic solvent). Along with the realization of dry-developable micropatterns, the chemical surface composition of the exposed areas can be conveniently adjusted since different domains with a tailored content of carboxylic groups are obtained simply by modulating the laser energy dose. In a following step, those are activated and exploited as anchor points for attaching an Alexa-546 conjugated Protein A. Thus, the laser writable thiol-ene networks do not only provide a convenient method for the fabrication of positive tone patterns but also open future prospectives for a wide range of biosensing applications.

Spatially Resolved Cross-Linking Characterization by Imaging Low-Coherence Interferometry.

A method to characterize cross-linking differences in polymers such as waveguide polymers has been developed. The method is based on the scan-free information acquisition utilizing a low-coherence interferometer in conjunction with an imaging spectrometer. By the introduction of a novel analyzing algorithm, the recorded spectral-phase data was interpreted as wavelength-dependent optical thickness which is matchable with the refractive index and therefore with the degree of cross-linking. In the course of this work, the method was described in its hardware and algorithmic implementation as well as in its accuracy. Comparative measurements and error estimations showed an accuracy in the range of 10-6 in terms of the refractive index. Finally, photo-lithographically produced samples with laterally defined cross-linking differences have been characterized. It could be shown, that differences in the optical thickness of ±1.5 µm are distinguishable.

Multi-Material 3D Printing of Biobased Epoxy Resins.

Additive manufacturing (AM) has revolutionised the manufacturing industry, offering versatile capabilities for creating complex geometries directly from a digital design. Among the various 3D printing methods for polymers, vat photopolymerisation combines photochemistry and 3D printing. Despite the fact that single-epoxy 3D printing has been explored, the fabrication of multi-material bioderived epoxy thermosets remains unexplored. This study introduces the feasibility and potential of multi-material 3D printing by means of a dual-vat Digital Light Processing (DLP) technology, focusing on bioderived epoxy resins such as ELO (epoxidized linseed oil) and DGEVA (vanillin alcohol diglycidyl ether). By integrating different materials with different mechanical properties into one sample, this approach enhances sustainability and offers versatility for different applications. Through experimental characterisation, including mechanical and thermal analysis, the study demonstrates the ability to produce structures composed of different materials with tailored mechanical properties and shapes that change on demand. The findings underscore the promising technology of dual-vat DLP technology applied to sustainable bioderived epoxy monomers, allowing sustainable material production and complex structure fabrication.

Digital light processing 3D printing of dynamic magneto-responsive thiol-acrylate composites.

Additive manufacturing is one of the most promising processing techniques for fabricating customized 3D objects. For the 3D printing of functional and stimuli-triggered devices, interest is steadily growing in processing materials with magnetic properties. Synthesis routes for magneto-responsive soft materials typically involve the dispersion of (nano)particles into a non-magnetic polymer matrix. Above their glass transition temperature, the shape of such composites can be conveniently adjusted by applying an external magnetic field. With their rapid response time, facile controllability, and reversible actuation, magnetically responsive soft materials can be used in the biomedical field (e.g. drug delivery, minimally invasive surgery), soft robotics or in electronic applications. Herein, we combine the magnetic response with thermo-activated healability by introducing magnetic Fe3O4 nanoparticles into a dynamic photopolymer network, which undergoes thermo-activated bond exchange reactions. The resin is based on a radically curable thiol-acrylate system, whose composition is optimized towards processability via digital light processing 3D printing. A mono-functional methacrylate phosphate is applied as a stabilizer to increase the resins' shelf life by preventing thiol-Michael reactions. Once photocured, the organic phosphate further acts as a transesterification catalyst and activates bond exchange reactions at elevated temperature, which render the magneto-active composites mendable and malleable. The healing performance is demonstrated by recovering magnetic and mechanical properties after the thermally triggered mending of 3D-printed structures. We further demonstrate the magnetically driven movement of 3D-printed samples, which gives rise to the potential use of these materials in healable soft devices activated by external magnetic fields.

Vitrimeric shape memory polymer-based fingertips for adaptive grasping.

The variability in the shapes and sizes of objects presents a significant challenge for two-finger robotic grippers when it comes to manipulating them. Based on the chemistry of vitrimers (a new class of polymer materials that have dynamic covalent bonds, which allow them to reversibly change their mechanical properties under specific conditions), we present two designs as 3D-printed shape memory polymer-based shape-adaptive fingertips (SMP-SAF). The fingertips have two main properties needed for an effective grasping. First, the ability to adapt their shape to different objects. Second, exhibiting variable rigidity, to lock and retain this new shape without the need for any continuous external triggering system. Our two design strategies are: 1) A curved part, which is suitable for grasping delicate and fragile objects. In this mode and prior to gripping, the SMP-SAFs are straightened by the force of the parallel gripper and are adapted to the object by shape memory activation. 2) A straight part that takes on the form of the objects by contact force with them. This mode is better suited for gripping hard bodies and provides a more straightforward shape programming process. The SMP-SAFs can be programmed by heating them up above glass transition temperature (54°C) via Joule-effect of the integrated electrically conductive wire or by using a heat gun, followed by reshaping by the external forces (without human intervention), and subsequently fixing the new shape upon cooling. As the shape programming process is time-consuming, this technique suits adaptive sorting lines where the variety of objects is not changed from grasp to grasp, but from batch to batch.

In Situ Observation of Micro-Patterned Elastomeric Surfaces: The Formation of the Area of Real Contact and the Influence on Its Friction and Deformation Behaviour.

Structured surfaces, which are the basis of the lotus blossom effect, have great potential to serve/operate as functionalised surfaces, i.e., surfaces with specific and/or adjustable properties. In the present study, the aim is to use micro-structured elastomeric surfaces to specifically influence the friction and deformation behaviours on the basis of the shape and arrangement of the structures. Thiol-acrylate-based photopolymers patterned via nanoimprint lithography were investigated by using an in situ tribological measurement set-up. A clear influence of the different structures on the surface's friction behaviour could be shown, and, furthermore, this could be brought into relation with the real area of contact. This finding provides an important contribution to further development steps, namely, to give the structures switchable properties in order to enable the control of friction properties in a targeted manner.

Water-developable poly(2-oxazoline)-based negative photoresists.

Copoly(2-oxazoline)-based photoresists are prepared from pEtOx(80) Bu(=) Ox(20) and pPhOx(80) Dc(=) Ox(20) , respectively, a tetrathiol, and a photosensitive initiator. It is possible to prepare copoly(2-oxazoline)s bearing unsaturated side chains in a microwave reactor on a decagram scale in reaction times of 100 min or shorter. UV irradiation of dried polymer films through a quartz mask induces the thiol-ene reaction in the illuminated areas. Subsequent development of the polymer films in halogen-free solvents reproduces the negative pattern of the mask with a resolution of 2 µm. The pEtOx(80) Bu(=) Ox(20) -derived photoresists can also be developed in water.

A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization.

Additive manufacturing or 3D printing of materials is a prominent process technology which involves the fabrication of materials layer-by-layer or point-by-point in a subsequent manner. With recent advancements in additive manufacturing, the technology has excited a great potential for extension of simple designs to complex multi-material geometries. Vat photopolymerization is a subdivision of additive manufacturing which possesses many attractive features, including excellent printing resolution, high dimensional accuracy, low-cost manufacturing, and the ability to spatially control the material properties. However, the technology is currently limited by design strategies, material chemistries, and equipment limitations. This review aims to provide readers with a comprehensive comparison of different additive manufacturing technologies along with detailed knowledge on advances in multi-material vat photopolymerization technologies. Furthermore, we describe popular material chemistries both from the past and more recently, along with future prospects to address the material-related limitations of vat photopolymerization. Examples of the impressive multi-material capabilities inspired by nature which are applicable today in multiple areas of life are briefly presented in the applications section. Finally, we describe our point of view on the future prospects of 3D printed multi-material structures as well as on the way forward towards promising further advancements in vat photopolymerization.

Vat Photopolymerization 3D-Printing of Dynamic Thiol-Acrylate Photopolymers Using Bio-Derived Building Blocks.

As an energy-efficient additive manufacturing process, vat photopolymerization 3D-printing has become a convenient technology to fabricate functional devices with high resolution and freedom in design. However, due to their permanently crosslinked network structure, photopolymers are not easily reprocessed or repaired. To improve the environmental footprint of 3D-printed objects, herein, we combine the dynamic nature of hydroxyl ester links, undergoing a catalyzed transesterification at elevated temperature, with an acrylate monomer derived from renewable resources. As a sustainable building block, we synthesized an acrylated linseed oil and mixed it with selected thiol crosslinkers. By careful selection of the transesterification catalyst, we obtained dynamic thiol-acrylate resins with a high cure rate and decent storage stability, which enabled the digital light processing (DLP) 3D-printing of objects with a structure size of 550 µm. Owing to their dynamic covalent bonds, the thiol-acrylate networks were able to relax 63% of their initial stress within 22 min at 180 °C and showed enhanced toughness after thermal annealing. We exploited the thermo-activated reflow of the dynamic networks to heal and re-shape the 3D-printed objects. The dynamic thiol-acrylate photopolymers also demonstrated promising healing, shape memory, and re-shaping properties, thus offering great potential for various industrial fields such as soft robotics and electronics.

Self-healable fiber-reinforced vitrimer composites: overview and future prospects.

To achieve sustainable development goals, approaches towards the preparation of recyclable and healable polymeric materials is highly attractive. Self-healing polymers and thermosets based on bond-exchangeable dynamic covalent bonds, so called "vitrimers" could be a great effort in this direction. In order to match the industrial importance, enhancement of mechanical strength without sacrificing the bond exchange capability is a challenging issue, however, such concerns can be overcome through the developments of fiber-reinforced vitrimer composites. This article covers the outstanding features of fiber-reinforced vitrimer composites, including their reprocessing, recycling and self-healing properties, together with practical applications and future perspectives of this unique class of materials.

Recent Trends in Applying Rrtho-Nitrobenzyl Esters for the Design of Photo-Responsive Polymer Networks.

Polymers with light-responsive groups have gained increased attention in the design of functional materials, as they allow changes in polymers properties, on demand, and simply by light exposure. For the synthesis of polymers and polymer networks with photolabile properties, the introduction o-nitrobenzyl alcohol (o-NB) derivatives as light-responsive chromophores has become a convenient and powerful route. Although o-NB groups were successfully exploited in numerous applications, this review pays particular attention to the studies in which they were included as photo-responsive moieties in thin polymer films and functional polymer coatings. The review is divided into four different sections according to the chemical structure of the polymer networks: (i) acrylate and methacrylate; (ii) thiol-click; (iii) epoxy; and (iv) polydimethylsiloxane. We conclude with an outlook of the present challenges and future perspectives of the versatile and unique features of o-NB chemistry.

Recent Advances in Functional Polymers Containing Coumarin Chromophores.

Natural and synthetic coumarin derivatives have gained increased attention in the design of functional polymers and polymer networks due to their unique optical, biological, and photochemical properties. This review provides a comprehensive overview over recent developments in macromolecular architecture and mainly covers examples from the literature published from 2004 to 2020. Along with a discussion on coumarin and its photochemical properties, we focus on polymers containing coumarin as a nonreactive moiety as well as polymer systems exploiting the dimerization and/or reversible nature of the [2πs + 2πs] cycloaddition reaction. Coumarin moieties undergo a reversible [2πs + 2πs] cycloaddition reaction upon irradiation with specific wavelengths in the UV region, which is applied to impart intrinsic healability, shape-memory, and reversible properties into polymers. In addition, coumarin chromophores are able to dimerize under the exposure to direct sunlight, which is a promising route for the synthesis and cross-linking of polymer systems under "green" and environment-friendly conditions. Along with the chemistry and design of coumarin functional polymers, we highlight various future application fields of coumarin containing polymers involving tissue engineering, drug delivery systems, soft robotics, or 4D printing applications.