Active light-controlled frontal ring-opening metathesis polymerization

D. R. Darby, A. J. Greenlee, R. H. Bean, D. C. Fairchild, V. C. Rodriguez, A. L. Jansen, S. C. Gallegos, S. P. Ramirez, J. S. Moore, S. C. Leguizamon () and L. N. Appelhans ()
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D. R. Darby: Sandia National Laboratories
A. J. Greenlee: Sandia National Laboratories
R. H. Bean: Sandia National Laboratories
D. C. Fairchild: Sandia National Laboratories
V. C. Rodriguez: Sandia National Laboratories
A. L. Jansen: Sandia National Laboratories
S. C. Gallegos: Sandia National Laboratories
S. P. Ramirez: Sandia National Laboratories
J. S. Moore: University of Illinois
S. C. Leguizamon: Sandia National Laboratories
L. N. Appelhans: Sandia National Laboratories

Nature Communications, 2025, vol. 16, issue 1, 1-11

Abstract: Abstract Frontal ring-opening metathesis polymerization (FROMP) is a promising energy-efficient approach to fabricate polymeric materials. Recent advances have demonstrated FROMP for diverse applications, including additive manufacturing, composites, and foams. However, the characteristic properties of the front are currently controlled primarily by varying the resin composition or the environmental conditions. In this work we present an approach to control FROMP of dicyclopentadiene (DCPD) using photochemical methods. A photobase generator is used to inhibit FROMP of DCPD with UV light while a photosensitizer and co-initiator are used to accelerate FROMP with blue light, enabling orthogonal active photocontrol of front velocity. In addition, photoinhibition-enabled lithographic patterning of frontal polymerizations is demonstrated. Frontal polymerizations are spatially controlled, redirected, and even split into diverging fronts. This work establishes a foundation for advanced control of frontal polymerizations, enabling innovation in traditional and additive manufacturing, as well as emerging processes like morphogenic manufacturing.

Date: 2025
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DOI: 10.1038/s41467-025-61484-9

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