Complex patterns
integral to the structure and function of biological
materials arise spontaneously during morphogenesis. In contrast, functional
patterns in synthetic materials are typically created through multistep
manufacturing processes, limiting accessibility to spatially varying
materials systems. Here, we harness rapid reaction-thermal transport
during frontal polymerization to drive the emergence of spatially
varying patterns during the synthesis of engineering polymers. Tuning
of the reaction kinetics and thermal transport enables internal feedback
control over thermal gradients to spontaneously pattern morphological,
chemical, optical, and mechanical properties of structural materials.
We
achieve patterned regions with two orders of magnitude change in modulus
in poly(cyclooctadiene) and 20 °C change in glass transition
temperature in poly(dicyclopentadiene). Our results suggest a facile
route to patterned structural materials with complex microstructures
without the need for masks, molds, or printers utilized in conventional
manufacturing. Moreover, we envision that more sophisticated control
of reaction-transport driven fronts may enable spontaneous growth
of structures and patterns in synthetic materials, inaccessible by
traditional manufacturing approaches.