Additive manufacturing (AM) methods such as material extrusion (ME) are becoming widely used by engineers, designers and hobbyists alike for a wide variety of applications. Successfully manufacturing objects using ME three-dimensional printers can often require numerous iterations to attain predictable performance because the exact mechanical behavior of parts fabricated via additive processes are difficult to predict. One of that factors that contributes to this difficulty is the wide variety of ME feed stock materials currently available in the marketplace. These build materials are often sold based on their base polymer material such as acrylonitrile butadiene styrene or polylactic acid (PLA), but are produced by numerous different commercial suppliers in a wide variety of colors using typically undisclosed additive feed stocks and base polymer formulations. This paper aims to present the results from an experimental study concerned with quantifying how these sources of polymer variability can affect the mechanical behavior of three-dimensional printed objects. Specifically, the set of experiments conducted in this study focused on following: several different colors of PLA filament from a single commercial supplier to explore the effect of color additives and three filaments of the same color but produced by three different suppliers to account for potential variations in polymer formulation.
Publications
100th Anniversary of Macromolecular Science Viewpoint: Integrating Chemistry and Engineering to Enable Additive Manufacturing with High-Performance Polymers
Additive manufacturing (AM) with high-performance polymers (HPPs) represents simultaneously one of the most desirable and challenging feats in the AM arena. The very properties that make HPPs so attractive in a broad range of applications also make them nearly impossible to process using common AM equipment. Furthermore, when AM is achieved, it often brings the caveat of compromised mechanical properties of the final parts, in comparison with those made via injection molding. The demand to have advanced fabrication methods, rapid prototyping, and customization of parts while maintaining high performance in the finished products has inspired creative innovations that integrate chemical synthesis, materials science, mechanical engineering, and other fields into a multidisciplinary approach to advance AM with the seemingly “unprintable” HPPs. In this Viewpoint, we summarize several standout developments in the area and offer our perspective on future directions and challenges.
Synthesis and characterization of anionic poly(cyclopentadienylene vinylene) and its use in conductive hydrogels.
The use of π‐conjugated polymers (CPs) in conductive hydrogels remains challenging due to the water‐insoluble nature of most CPs. Conjugated polyelectrolytes (CPEs) are promising alternatives because they have tunable electronic properties and high water‐solubility, but they are often difficult to synthesize and thus have not been widely adopted. Herein, we report the synthesis of an anionic poly(cyclopentadienylene vinylene) (aPCPV) from an insulating precursor under mild conditions and in high yield. Functionalized aPCPV is a highly water‐soluble CPE that exhibits low cytotoxicity, and we found that doping hydrogels with aPCPV imparts conductivity. We also anticipate that this precursor synthetic strategy, due to its ease and high efficiency, will be widely used to create families of not‐yet‐explored π‐conjugated vinylene polymers.
Molecular Weight Control via Cross Metathesis in Photo‐Redox Mediated Ring‐Opening Metathesis Polymerization
Photo-redox mediated ring-opening metathesis polymerization (photo-ROMP) is an emerging ROMP technique that uses an organic redox mediator and a vinyl ether initiator, in contrast to metal-based initiators traditionally used in ROMP. The reversibility of the redox-mediated initiation and propagation steps enable spatiotemporal control over the polymerization. Herein, we explore a simple, inexpensive means of controlling molecular weight, using alpha olefins as chain transfer agents. This method enables access to low molecular weight oligomers, and molecular weights between 1 and 30 kDa can be targeted simply by altering the stoichiometry of the reaction. This method of molecular weight control was then used to synthesize a functionalized norbornene copolymer in a range of molecular weights for specific materials applications.
Reduced Strain Mechanochemical Activation Onset in Microstructured Materials
In this study, we show that mechanochemical activation in responsive materials with designed, periodic microstructures can be achieved at lower applied strains than their bulk counterparts. Furthermore, by characterizing two responsive polymeric materials, we have developed a computational model capable of quantitatively predicting mechanochemical activation in geometrically complex structures.
Ring-opening metathesis polymerization of a strained stilbene-based macrocyclic monomer
We report the synthesis of a new class of strained macrocycle that performs well in ring-opening metathesis polymerization (ROMP). The polymerization displays chain growth characteristics with evidence of secondary metathesis in the form of chain transfer. The unique structure enables access to stilbene-based polymers that are traditionally prepared via uncontrolled polymerizations.
Hybrid Photo-induced Copolymerization of Ring-Strained and Vinyl Monomers Utilizing Metal-Free Ring-Opening Metathesis Polymerization Conditions
We introduce the hybrid copolymerization of two disparate monomer classes (vinyl monomers and ring-strained cyclic olefins) via living photopolymerization. The living character of the polymerization technique (metal-free photo-ROMP) is demonstrated by consecutive chain-extensions. Further, we propose a mechanism for the copolymerization and analyze the copolymer structure in detail by high-resolution mass spectrometry.
Room Temperature Extrusion 3D Printing of Polyether Ether Ketone Using a Stimuli-Responsive Binder
We report our efforts toward 3D printing of polyether ether ketone (PEEK) at room temperature by direct-ink write technology. The room-temperature extrusion printing method was enabled by a unique formulation comprised of commercial PEEK powder, soluble epoxy-functionalized PEEK (ePEEK), and fenchone. This combination formed a Bingham plastic that could be extruded using a readily available direct-ink write printer. The initial green body specimens were strong enough to be manipulated manually after drying. After printing, thermal processing at 230 °C resulted in crosslinking of the ePEEK components to form a stabilizing network throughout the specimen, which helped to preclude distortion and cracking upon sintering. A final sintering stage was conducted at 380 °C. The final parts were found to have excellent thermal stability and solvent resistance. The Tg of the product specimens was found to be 158 °C, which is 13 °C higher than commercial PEEK as measured by DSC. Moreover, the thermal decomposition temperature was found to be 528 °C, which compares well against commercial molded PEEK samples. Chemical resistance in trifluoroacetic acid and 8 common organic solvents, including CH2Cl2 and toluene, were also investigated and no signs of degradation or weight changes were observed from parts submerged for 1 week in each solvent. Test specimens also displayed desirable mechanical properties, such as a Young’s modulus of 2.5 GPa, which corresponds to 63% of that of commercial PEEK (reported to be 4.0 GPa).
Stimuli-Responsive Materials in Additive Manufacturing
Additive manufacturing (AM) technologies are expanding the boundaries of materials science and providing an exciting forum for interdisciplinary research. The ability to fabricate arbitrarily complex objects has made AM technologies indispensable in personalized healthcare, soft electronics, and renewable energy. At the intersection of AM technologies and materials chemistry are stimuli-responsive polymers, which change their chemical and physical properties in response to specific environmental cues. The responsiveness of these “smart” polymers makes them suitable for AM and provides functionality to the additively manufactured objects. Furthermore, the type and degree of stimulus response of smart polymers can be regulated through precise synthetic design or via incorporation of additives. Herein, we review recently reported stimuli-responsive polymers used in AM, with a focus on the design and chemistry of the polymers. The materials are broadly classified by type of printing, and more specifically classified by type of stimulus response. Finally, we briefly consider existing challenges that stimuli-responsive materials in AM can address in the future.
Multimaterial Actinic Spatial Control 3D and 4D Printing
Production of objects with varied mechanical properties is challenging for current manufacturing methods. Additive manufacturing could make these multimaterial objects possible, but methods able to achieve multimaterial control along all three axes of printing are limited. Here we report a multi-wavelength method of vat photopolymerization that provides chemoselective wavelength-control over material composition utilizing multimaterial actinic spatial control (MASC) during additive manufacturing. The multicomponent photoresins include acrylate- and epoxide-based monomers with corresponding radical and cationic initiators. Under long wavelength (visible) irradiation, preferential curing of acrylate components is observed. Under short wavelength (UV) irradiation, a combination of acrylate and epoxide components are incorporated. This enables production of multimaterial parts containing stiff epoxide networks contrasted against soft hydrogels and organogels. Variation in MASC formulation drastically changes the mechanical properties of printed samples. Samples printed using different MASC formulations have spatially-controlled chemical heterogeneity, mechanical anisotropy, and spatially-controlled swelling that facilitates 4D printing.