The incorporation of structural color into 3D printed parts is reported, presenting an alternative to the need for pigments or dyes for colored parts produced through additive manufacturing. Thermoplastic build materials composed of dendritic block copolymers were designed, synthesized, and used to additively manufacture plastic parts exhibiting structural color. The reflection properties of the photonic crystals arise from the periodic nanostructure formed through block copolymer self-assembly during polymer processing. The wavelength of reflected light could be tuned across the visible spectrum by synthetically controlling the block copolymer molecular weight and manufacture parts that reflected violet, green, or orange light with the capacity to serve as selective optical filters and light guides.Keywords: additive manufacturing; block copolymers; photonic crystals; self-assembly; structural color;

Organic photoredox catalysts have been shown to operate organocatalyzed atom transfer radical polymerizations (O-ATRP) using visible light as the driving force. In this work, the effect of light intensity from white LEDs was evaluated as an influential factor in control over the polymerization and the production of well-defined polymers. We posit the irradiation conditions control the concentrations of various catalyst states necessary to mediate a controlled radical polymerization. Systematic dimming of white LEDs allowed for consideration of the role of light intensity on the polymerization performance. The general effects of decreased irradiation intensity in photoinduced O-ATRP were investigated through comparing two different organic photoredox catalysts: perylene and an 3,7-di(4-biphenyl) 1-naphthalene-10-phenoxazine. Previous computational efforts have investigated catalyst photophysical and electrochemical characteristics, but the broad and complex effects of varied irradiation intensity as an experimental variable on the mechanism of O-ATRP have not been explored. This work revealed that perylene requires more stringent irradiation conditions to achieve controlled polymer molecular weight growth and produce polymers with dispersities <1.50. In contrast, the 3,7-di(4-biphenyl) 1-naphthalene-10-phenoxazine is more robust, achieving linear polymer molecular weight growth under relative irradiation intensity as low as 25%, to produce polymers with dispersities <1.50. This finding is significant, as the discovery of highly robust catalysts is necessary to allow for the adoption of successful O-ATRP in a wide scope of conditions, including those which necessitate low light intensity irradiation.

Organocatalyzed atom transfer radical polymerization (O-ATRP) has emerged as a metal-free variant of historically transition-metal reliant atom transfer radical polymerization. Strongly reducing organic photoredox catalysts have proven capable of mediating O-ATRP. To date, operation of photoinduced O-ATRP has been demonstrated in batch reactions. However, continuous flow approaches can provide efficient irradiation reaction conditions and thus enable increased polymerization performance. Herein, the adaptation of O-ATRP to a continuous flow approach has been performed with multiple visible-light absorbing photoredox catalysts. Using continuous flow conditions, improved polymerization results were achieved, consisting of narrow molecular weight distributions as low as 1.05 and quantitative initiator efficiencies. This system demonstrated success with 0.01% photocatalyst loadings and a diverse methacrylate monomer scope. Additionally, successful chain-extension polymerizations using 0.01 mol % photocatalyst loadings reveal continuous flow O-ATRP to be a robust and versatile method of polymerization.

Photoexcited intramolecular charge transfer (CT) states in N,N-diaryl dihydrophenazine photoredox catalysts are accessed through catalyst design and investigated through combined experimental studies and density functional theory (DFT) calculations. These CT states are reminiscent of the metal to ligand charge transfer (MLCT) states of ruthenium and iridium polypyridyl complexes. For cases where the polar CT state is the lowest energy excited state, we observe its population through significant solvatochromic shifts in emission wavelength across the visible spectrum by varying solvent polarity. We propose the importance of accessing CT states for photoredox catalysis of atom transfer radical polymerization lies in their ability to minimize fluorescence while enhancing electron transfer rates between the photoexcited photoredox catalyst and the substrate. Additionally, solvent polarity influences the deactivation pathway, greatly affecting the strength of ion pairing between the oxidized photocatalyst and the bromide anion and thus the ability to realize a controlled radical polymerization. Greater understanding of these photoredox catalysts with respect to CT and ion pairing enables their application toward the polymerization of methyl methacrylate for the synthesis of polymers with precisely tunable molecular weights and dispersities typically lower than 1.10.

N-Aryl phenoxazines have been synthesized and introduced as strongly reducing metal-free photoredox catalysts in organocatalyzed atom transfer radical polymerization for the synthesis of well-defined polymers. Experiments confirmed quantum chemical predictions that, like their dihydrophenazine analogs, the photoexcited states of phenoxazine photoredox catalysts are strongly reducing and achieve superior performance when they possess charge transfer character. We compare phenoxazines to previously reported dihydrophenazines and phenothiazines as photoredox catalysts to gain insight into the performance of these catalysts and establish principles for catalyst design. A key finding reveals that maintenance of a planar conformation of the phenoxazine catalyst during the catalytic cycle encourages the synthesis of well-defined macromolecules. Using these principles, we realized a core substituted phenoxazine as a visible light photoredox catalyst that performed superior to UV-absorbing phenoxazines as well as previously reported organic photocatalysts in organocatalyzed atom transfer radical polymerization. Using this catalyst and irradiating with white LEDs resulted in the production of polymers with targeted molecular weights through achieving quantitative initiator efficiencies, which possess dispersities ranging from 1.13 to 1.31.

The generation of carbon-centered radicals from alkyl bromides through an oxidative quenching pathway using perylene as an organic visible-light photocatalyst is described. This methodology is used to initiate the radical polymerization of methyl methacrylate and other functionalized vinyl monomers. The polymers possess bromide chain-end groups that can be used to reinitiate polymerization to produce block copolymers. Control over the polymerization propagation can be achieved through pulsed light sequences while the ability to use natural sunlight to promote carbon–carbon bond formation produces polymers with dispersity as low as 1.29.