Related Experiment Video
Updated: Jan 17, 2026
07:28
3D Printing and In Situ Surface Modification via Type I Photoinitiated Reversible Addition-Fragmentation Chain Transfer Polymerization
Published on: February 18, 2022
4.2K
3D Printing of Poly(methyl methacrylate) by Interfacial Photopolymerization
Prajwal Tumkur Mahesh1, Cécile A C Chazot2, Richard B Church1,3
1Department of Mechanical Engineering, Massachusetts Institute of Technology, Cambridge, Massachusetts 02141, United States.
ACS Applied Materials & Interfaces
|September 16, 2025
Summary
This study introduces interfacial photopolymerization (IPP) 3D printing for creating recyclable thermoplastic parts. This sustainable method enables low-waste production of complex polymer components with potential for multiple reuse cycles.
Area of Science:
- Polymer Chemistry
- Additive Manufacturing
- Materials Science
Background:
- Established light-based additive manufacturing (AM) processes often use non-recyclable thermoset polymers, raising sustainability concerns.
- There is a growing demand for low-waste production of complex, high-resolution polymer parts using sustainable methods.
Purpose of the Study:
- To present a novel method for circular photopolymerization 3D printing of thermoplastic parts.
- To demonstrate a new chemistry for interfacial photopolymerization (IPP) and a process for multilayer fabrication.
- To address the limitations of previous IPP methods regarding chemistry and 3D structural control.
Main Methods:
- Utilized interfacial photopolymerization (IPP) to form linear polymer chains into entangled networks at the interface of immiscible organic and aqueous phases.
- Developed a specific chemistry for poly(methyl methacrylate) (PMMA) formation via IPP.
- Modified a commercial projector-based 3D printer for multilayer fabrication, incorporating a light-absorbing dye and polyethylene glycol (PEG) binder for enhanced resolution and stability.
- Implemented controlled air drying and thermal treatment with PEG infiltration for postprocessing to preserve geometry and reduce cracking.
Main Results:
- Successfully formed poly(methyl methacrylate) (PMMA) using IPP.
- Achieved multilayer fabrication of thermoplastic parts in a modified 3D printer.
- The resulting composite material consists of 75% PEG and 25% PMMA, exhibiting mechanical properties similar to polymer foams.
- Demonstrated the circularity of the IPP-PMMA process through successful recycling and reincorporation of printed objects over several cycles without significant property degradation.
Conclusions:
- Interfacial photopolymerization (IPP) 3D printing enables, for the first time, digital light processing of recyclable thermoplastic PMMA and PEG-based parts.
- The developed process offers a sustainable alternative for producing complex polymer parts with reduced waste.
- Further enhancements in geometric fidelity and mechanical properties are needed for broader applications, but the foundational technology is established.
