We investigate the frontal photopolymerization of a thiol–ene system with a combination of experiments and modeling, focusing on the interfacial conversion profile and its planar wave propagation. We spatially resolve the solid-to-liquid front by FT-IR and AFM mechanical measurements, supplemented by differential scanning calorimetry. A simple coarse-grained model is found to describe remarkably well the frontal kinetics and the sigmoidal interface, capturing the effects of UV light exposure time (or dose) and temperature, as well as the front position and resulting patterned dimensions after development. Analytical solutions for the conversion profile enable the description of all conditions with a single master curve in the moving frame of the front position. Building on this understanding, we demonstrate the design and fabrication of gradient polymer materials, with tunable properties along the direction of illumination, which can be coupled with lateral patterning by modulated illumination or grayscale lithography.

A unified patterning strategy via frontal photopolymerization (FPP) that is robust to a wide range of radical photopolymerizing systems, including thiol-ene and acrylic monomers is reported. The factors governing the spatiotemporal solidification process, including front position, profile shape, and thermal effects, are investigated and modeled theoretically, resulting in the predictive FPP patterning of polymer networks with prescribed dimensions.

No abstract

Frontal photopolymerization (FPP) is a versatile directional solidification process that can be used to rapidly fabricate polymer network materials by selectively exposing a photosensitive monomer bath to light. A characteristic feature of FPP is that the monomer-to-polymer conversion profiles take on the form of traveling waves that propagate into the unpolymerized bulk from the illuminated surface. Practical implementations of FPP require detailed knowledge about the conversion profile and speed of these traveling waves. The purpose of this theoretical study is to (i) determine the conditions under which FPP occurs and (ii) explore how optical attenuation and mass transport can be used to finely tune the conversion profile and propagation kinetics. Our findings quantify the strong optical attenuation and slow mass transport relative to the rate of polymerization required for FPP. The shape of the traveling wave is primarily controlled by the magnitude of the optical attenuation coefficients of the neat and polymerized material. Unexpectedly, we find that mass diffusion can increase the net extent of polymerization and accelerate the growth of the solid network. The theoretical predictions are found to be in excellent agreement with experimental data acquired for representative systems.

We present a full kinetic model of a hydrogel that undergoes phase separation during swelling and deswelling. The model accounts for the interfacial energy of coexisting phases, finite strain of the polymer network, and solvent transport across free boundaries. For the geometry of an initially dry layer bonded to a rigid substrate, the model predicts that forcing solvent into the gel at a fixed rate can induce a volume phase transition, which gives rise to coexisting phases with different degrees of swelling, in systems where this cannot occur in the freeswelling case. While a nonzero shear modulus assists in the propagation of the transition front separating these phases in the driven-swelling case, increasing it beyond a critical threshold suppresses its formation. Quenching a swollen hydrogel induces spinodal decomposition, which produces several highly localized, highly swollen phases which coarsen and are then ejected from free boundary. The wealth of dynamic scenarios of this system is discussed using phase-plane analysis and numerical solutions in a one-dimensional setting.