Collaborative Research: Interfacial Photopolymerization (IPP): A Method For High-Resolution Digital Printing of Thermoplastics

合作研究：界面光聚合（IPP）：一种热塑性塑料高分辨率数字印刷方法

• 批准号: 2114343
• 负责人: Anastasios John Hart
• 金额: $ 38.22万
• 依托单位: Massachusetts Institute of Technology
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2021
• 资助国家: 美国
• 起止时间: 2021-09-01 至 2024-08-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2114343&HistoricalAwards=false
• 关键词: Collaborative; Research; Interfacial; Photopolymerization; IPP

Additive manufacturing (AM) encompasses many technologies used to produce objects by successive addition of material in a layer-by-layer manner. Currently, AM techniques for thermoplastic polymers rely on local heating to melt and reshape the material. AM processes that form objects by photopolymerization rely on an intrinsic crosslinking mechanism in thermoset polymers. These photopolymerization AM methods can produce parts with superior surface finish and detail relative to the methods available for thermoplastics, but these attributes come at the expense of compatibility with large-scale recycling processes. This award will support research on the first AM technique for recyclable thermoplastic materials that utilizes photopolymerization, called Interfacial Photopolymerization (IPP). This work combines fundamental materials science and manufacturing scale-up to enable the digital production of intricate, high resolution thermoplastic objects using commercially available feedstock materials. This work will have economic and environmental benefits by opening new applications in automotive, aerospace, consumer, and medical device industries that use recyclable plastics, which is a vital contribution to the sustainability of our world. In IPP, the polymerization process and resolution are controlled by a LED light source, which is focused at the reaction zone located at or near a planar liquid-liquid interface. Realization of this technology requires a detailed investigation into fundamental transport and reaction kinetics, light management conditions, and chemical thermodynamics to elucidate the governing physical mechanisms for polymer formation and the role they play in final print quality (e.g., resolution, interlayer adhesion, mechanical properties). A macrokinetic model of the diffusion and precipitation at the interface will be developed to establish quantitative understanding of how single layers form in IPP and the fundamental limits and parameter tradeoffs, and a custom-built projector-based 3D printer will be used to fabricate demonstration objects. Data on process and material performance will be integrated into cost models to compare IPP to AM and injection molding methods for polymer manufacturing and evaluate the economic viability of IPP at industrial scale.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

增材制造（AM）涵盖了许多用于通过逐层方式连续添加材料来生产对象的技术。目前，热塑性聚合物的AM技术依赖于局部加热来融化和重塑材料。通过光聚合形成对象的AM过程依赖于热固性聚合物中的固有交联机制。这些光聚合AM方法相对于热塑性塑料可用的方法可以产生具有优越的表面表面和细节的部分，但是这些属性是以与大型回收过程相容的代价。该奖项将支持对利用光聚合作用的可回收热塑性材料的第一个AM技术的研究，称为界面光聚合（IPP）。这项工作结合了基本材料科学和制造规模，以便使用市售的原料材料来实现复杂的高分辨率热塑性物体的数字生产。这项工作将通过在使用可回收塑料的汽车，航空航天，消费者和医疗设备行业中开放新的应用程序，从而获得经济和环境福利，这是对我们世界可持续性的重要贡献。在IPP中，聚合过程和分辨率由LED光源控制，该LED光源集中在位于平面液体液体界面或附近的反应区。实现这项技术需要详细研究基本运输和反应动力学，光管理条件和化学热力学，以阐明聚合物形成的治理物理机制及其在最终印刷质量中所起的作用（例如，分辨率，间层间，层间粘附器，机械性能）。将开发界面扩散和降水的宏动力学模型，以确定对IPP中的单层形成以及基本限制和参数权衡的方式的定量理解，以及基于定制的投影仪的3D打印机将用于制造演示对象。有关过程和材料性能的数据将集成到成本模型中，以将IPP与AM和聚合物制造的注射成型方法进行比较，并评估IPP在工业规模上的经济生存能力。该奖项反映了NSF的法定任务，并被认为是值得通过基金会的知识分子优点和更广泛影响的评估来通过评估来支持的。

项目成果

Interfacial Photopolymerization: A Method for Light-Based Printing of Thermoplastics

• DOI: 10.1021/acsami.3c04803
• 发表时间: 2023-06-13
• 期刊: ACS APPLIED MATERIALS & INTERFACES
• 影响因子: 9.5
• 作者: Chazot，Cecile A. C.;Creighton，Megan A.;Hart，A. John
• 通讯作者: Hart，A. John