A renewably sourced, circular photopolymer resin for additive manufacturing

Thiago O. Machado, Connor J. Stubbs, Viviane Chiaradia, Maher A. Alraddadi, Arianna Brandolese, Joshua C. Worch () and Andrew P. Dove ()
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Thiago O. Machado: Edgbaston
Connor J. Stubbs: Edgbaston
Viviane Chiaradia: Edgbaston
Maher A. Alraddadi: Edgbaston
Arianna Brandolese: Edgbaston
Joshua C. Worch: Edgbaston
Andrew P. Dove: Edgbaston

Nature, 2024, vol. 629, issue 8014, 1069-1074

Abstract: Abstract The additive manufacturing of photopolymer resins by means of vat photopolymerization enables the rapid fabrication of bespoke 3D-printed parts. Advances in methodology have continually improved resolution and manufacturing speed, yet both the process design and resin technology have remained largely consistent since its inception in the 1980s1. Liquid resin formulations, which are composed of reactive monomers and/or oligomers containing (meth)acrylates and epoxides, rapidly photopolymerize to create crosslinked polymer networks on exposure to a light stimulus in the presence of a photoinitiator2. These resin components are mostly obtained from petroleum feedstocks, although recent progress has been made through the derivatization of renewable biomass3–6 and the introduction of hydrolytically degradable bonds7–9. However, the resulting materials are still akin to conventional crosslinked rubbers and thermosets, thus limiting the recyclability of printed parts. At present, no existing photopolymer resin can be depolymerized and directly re-used in a circular, closed-loop pathway. Here we describe a photopolymer resin platform derived entirely from renewable lipoates that can be 3D-printed into high-resolution parts, efficiently deconstructed and subsequently reprinted in a circular manner. Previous inefficiencies with methods using internal dynamic covalent bonds10–17 to recycle and reprint 3D-printed photopolymers are resolved by exchanging conventional (meth)acrylates for dynamic cyclic disulfide species in lipoates. The lipoate resin platform is highly modular, whereby the composition and network architecture can be tuned to access printed materials with varied thermal and mechanical properties that are comparable to several commercial acrylic resins.

Date: 2024
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DOI: 10.1038/s41586-024-07399-9

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