The
driving of rapid polymerizations with visible to near-infrared
light will enable nascent technologies in the emerging fields of bio-
and composite-printing. However, current photopolymerization strategies
are limited by long reaction times, high light intensities, and/or
large catalyst loadings. The improvement of efficiency remains elusive
without a comprehensive, mechanistic evaluation of photocatalysis
to better understand how composition relates to polymerization metrics.
With this objective in mind, a series of methine- and aza-bridged
boron dipyrromethene (BODIPY) derivatives were synthesized and systematically
characterized to elucidate key structure–property relationships
that facilitate efficient photopolymerization driven by visible to
far-red light. For both BODIPY scaffolds, halogenation was shown as
a general method to increase polymerization rate, quantitatively characterized
using a custom real-time infrared spectroscopy setup. Furthermore,
a combination of steady-state emission quenching experiments, electronic
structure calculations, and ultrafast transient absorption revealed
that efficient intersystem crossing to the lowest excited triplet
state upon halogenation was a key mechanistic step to achieving rapid
photopolymerization reactions. Unprecedented polymerization rates
were achieved with extremely low light intensities (<1 mW/cm2) and catalyst loadings (<50 μM), exemplified by
reaction completion within 60 s of irradiation using green, red, and
far-red light-emitting diodes. Halogenated BODIPY photoredox catalysts
were additionally employed to produce complex 3D structures using
high-resolution visible light 3D printing, demonstrating the broad
utility of these catalysts in additive manufacturing.