Nanostructure design of 3D printed materials through macromolecular architecture

Polymerization-induced microphase separation (PIMS) has been previously combined with 3D printing to develop customized nanostructured materials with a wide range of functional applications. In traditional PIMS, monofunctional, linear macromolecular chain transfer agents (macroCTAs) are used to develop macroCTA-b-P(monomer-stat-crosslinker) networks that self-assemble into unique disordered nanostructures. In this work, we designed a significantly altered network structure by utilizing linear macroCTAs with pendant CTA groups, which provides a novel network upon polymerization (i.e., branched copolymers, [macroCTA-graft-[P(monomer-stat-crosslinker)]n]-b-P(monomer-stat-crosslinker)). Intriguingly, this method leads to the development of alternative disordered morphologies where the internal nanostructure can be precisely controlled. By systematically varying the number of pendant CTA groups, we demonstrate controlled transitions in macroCTA domain continuity, nanodomain size, and phase interface sharpness. These tunable properties translate to adjustable mechanical and swelling behaviors in the resulting 3D printed objects, ultimately enabling the fabrication of smart 4D materials (swelling-induced actuators and temperature-responsive shape-morphing objects). This research significantly expands the design toolbox for 3D printed PIMS materials, providing increased flexibility in the development of advanced materials with specific nanostructures and functionalities.