Radical photoinitiation with LEDs and applications in the 3D printing of composites

Radical initiation upon LED light irradiation is discussed herein as well as its application in additive manufacturing. The ability of manufacturing complex structures, freedom of design, low energy consumption, fast prototyping, and excellent spatial resolution are the main benefits of the 3D printing technology by photopolymerization. Therefore, the 3D printing of composites through photopolymerization processes is developing rapidly in the academia and industry, and has been a turning point of additive manufacturing (AM). In the present review, an overview of radical initiation with LEDs (i.e., the photopolymerization LED technology, the photoinitiating systems, and the polymerizable media) and of the main 3D printing methods by photopolymerization, materials, and their applications in different fields has been carried out. As a challenging topic, the issue of light penetration in a filled matrix for the access to composites is discussed, including the light transmittance of the composite, the mismatch of the refractive index between the filler and the monomer, the factors of the filler, and the adverse influence of low light penetration on the 3D printing process. In particular, the popular applications of 3D printing by photopolymerization in biomedical science, electronic industry, materials for adsorption, and 4D printing are discussed. Overall, this review gives an overview of the 3D printing of polymer matrix composites through photopolymerization processes as a benchmark for future research and development.