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Visible-Light-Fueled Polymerizations for 3D Printing.

Lynn M Stevens1, Nirvana T Almada1, Hyeong Seok Kim1

  • 1Department of Chemistry, The University of Texas at Austin, 105 East 24th Street, Austin, Texas 78712, United States.

Accounts of Chemical Research
|January 6, 2025
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Summary
This summary is machine-generated.

Researchers developed new photochemical systems for 3D printing using visible and near-infrared light, overcoming limitations of UV-based methods. This enables faster, high-resolution printing with diverse materials for advanced manufacturing.

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Area of Science:

  • Photochemistry and Polymer Science
  • Materials Science and Engineering
  • Additive Manufacturing

Background:

  • Current 3D printing relies heavily on UV light, facing limitations like oxygen sensitivity and restricted material scope.
  • The "ZAP" group addresses these hurdles by developing novel photochemical systems for light-driven polymerizations.
  • Advancements aim to enable rapid, controlled plastic formation using non-traditional light sources.

Purpose of the Study:

  • To develop photochemical systems responsive to visible and near-infrared (NIR) light for 3D printing.
  • To overcome limitations of UV-based photopolymerization, including speed, oxygen sensitivity, and material compatibility.
  • To implement these systems in vat photopolymerization for advanced additive manufacturing applications.

Main Methods:

  • Development of boron dipyrromethene (BODIPY) dyes as photoradical generators (PRGs) for radical polymerization.
  • Synthesis of photobase generators (PBGs) for nonradical polymerization of thiol-ene and thiol-isocyanate resins.
  • Implementation of reactive photoredox catalyst systems, additives for oxygen tolerance, and triplet fusion techniques.

Main Results:

  • BODIPY dyes enabled efficient polymerization of acrylics using visible-to-NIR light in seconds.
  • PBGs facilitated photocuring of diverse resins, expanding material capabilities beyond acrylics.
  • Achieved rapid, high-resolution 3D printing speeds up to 45 mm/h with features <100 μm, rivaling UV technologies.

Conclusions:

  • The developed photochemical systems offer practical solutions for additive manufacturing of (multi)functional materials.
  • Enabling lower-energy light sources leads to more environmentally friendly, cost-effective, and versatile 3D printing.
  • Paves the way for printing UV-sensitive compounds, nanocomposites, and multimaterial objects with precise control.