Open Access Article
Susana
Ferrufino Amador
a,
Rudy
White
a,
Olivia
Downey
a,
Kayla
Foy
a,
Rachel
Wynn
a,
Hawa
Khan
a,
Megan
O'Neil
b,
Olivia
McNair
b and
Samrat
Dutta
*a
aDepartment of Chemistry, Xavier University of Louisiana, New Orleans, LA 70125, USA. E-mail: sdutta@xula.edu
bSchool of Polymer Science and Engineering, The University of Southern Mississippi, Hattiesburg, MS 39406, USA
First published on 25th March 2026
Polymeric ionic liquids are a diverse class of ion-conducting materials with tunable properties that can advance the applicability of additive manufacturing. However, the potential of 3D UV printing of polymeric ionic liquids with metallic fillers for electronic applications remains somewhat limited. In this work, we formulated photocurable resins using a methacrylate-based ionic liquid monomer and a crosslinker, with and without gold nanoparticles as fillers. Our results show that centimeter-scale structures, both free-standing and bonded to a substrate, can be prepared straightforwardly from the formulations using commercial 3D UV printers. The printed structures exhibited high fidelity, a high degree of polymerization, and high thermal stability, with stiffness ranging from 0.2 GPa to 0.5 GPa. Increasing the content of gold nanoparticles in the ionic liquid composites increased the glass transition temperature from −23 °C to −3.5 °C. Polymers without gold nanoparticles had a conductivity of 10−6 S cm−1, which increased to 10−4 S cm−1 in prints with 1 wt% of gold nanoparticles. 3D-printed resistors made from 1 wt% of gold nanoparticles maintained a stable current profile for several hours. Such a result highlights the potential to prepare ionic-liquid-based flexible electronic components using commercial 3D UV printers.
Imidazolium-based ionic liquids are a class of non-homogeneous fluids that are entirely made of ions.16,17 These liquids can be converted into a solid form through the attachment and subsequent propagation through a polymerizable chemical group inserted onto ionic liquid molecules.18,19 Numerous combinations of imidazolium cations and their associated anions can be chemically modified into polymerizable monomers.20,21 If such an ionic liquid monomer is photocurable and compatible with 3D UV printing, the formulations can be utilized to build user-defined PIL structures.22–26 Many challenges intrinsic to 3D UV printing, including but not limited to developing curing protocols, identifying developing solvents, and establishing post-curing methods, also arise in photocurable ionic liquid formulations.27–29 In many cases,30–32 derivatives of 1-vinyl-3-alkyl imidazolium with different counter anions are used in formulations for 3D UV printing, but the vinyl group is less photoactive than acrylate or methacrylate.31 Also, there is a trend in the literature to use non-ionic crosslinkers, such as poly(ethylene glycol) dimethacrylate, in formulations.33,34 It should be noted that mixing components in photocurable resins with different polarities can cause inhomogeneity in 3D-printed structures, which can lead to phase segregation over the long term.35,36 Also, for prototyping, it is necessary to minimize the amount of the starting resin, as ionic liquids are expensive. An understated limitation of broadening the use of PILs is their compatibility with commercial 3D UV printers, particularly those that use liquid crystal display (LCD) projectors. The incident UV light on the resin of LCD UV printers has low intensity, with an average power per surface area of 2–10 mW cm−2. Photocurable ionic liquid resins that yield printed structures capable of addressing the above challenges are required for material adoption.
If the application of 3D UV-printed PIL structures is directed towards electronics, it is necessary to harness the intrinsic ionic conductivity of PILs.37–40 However, the electrical conductivity of PILs is 100 times lower than that of their parent ionic liquids5 (typically in the range of 10−5 S cm−1 or lower) and lower than other electrically conductive polymers41–43 such as poly(3,4-ethylene dioxythiophene):poly(styrenesulfonate) (PEDOT:PSS).44 This limitation can be overcome through the addition of a secondary component capable of enhancing the electrical conductivity. Researchers have previously added ionic liquids to the PIL matrix,45–47 as well as perovskite nanocrystals (PS-NCs), polyoxometalates (POMs), or carbon-based materials to photocurable ionic liquid formulations48–51 to improve the electrical conductance of PIL composites. However, many of these hybrid systems have not been examined within the framework of SLA technology.6
Sevilia et al.52 demonstrated that formulations in which both the monomer and the crosslinker are ionic liquids exhibit improved electrical conductivity. Au NP–ionic liquid-derived polymer composites were earlier shown to enhance electrical conductivity.53–55 Our novel strategy, therefore, combines three previously proven methodologies to enhance electrical conductivity and appropriate UV response to target 3D UV print techniques in PIL systems: (1) synthesis of ionic liquid monomers based on highly photoreactive methacrylate chemistry, so that they are compatible with commercial 3D UV printers, (2) utilization of a methacrylate-based ionic liquid crosslinker to increase ion density in the cured network, and (3) the addition of a metal dopant, in this case, Au-NPs, to alter the properties of PILs, particularly their electrical conductivities. The overarching strategy of preparing photocurable formulations composed entirely of ionic liquid components will eliminate inhomogeneity associated with mixing components of different polarities.
Monomers of imidazolium-based ionic liquids where the methacrylate group is stationed on the cation are extensively described in the literature.21,33,56–58 Recently, 3D UV-printed PILs of imidazolium-based ionic liquids with polymerizable anions bearing a methacrylate group have been reported, but they showed poor conductivity.59 Simulations on PILs based on imidazolium-based ionic liquids, where the cation is polymerized, have been extensively studied and show that conductivity is higher when associated with smaller counterions.7,38,60 Imidazolium-based PIL matrices prepared from formulations entirely of ionic liquid components, in which the imidazolium cation is methacrylate-functionalized and paired with a small counterion, and which are compatible with 3D UV printing, are missing from the literature. To realize our goals, we synthesized a monofunctional photopolymerizable ionic liquid monomer, 1-(2-methacryloyloxy)ethyl-3-butylimidazolium bromide, and a photopolymerizable ionic liquid crosslinker, 3-butyl-1,2-bis(2-(methacryloyloxy)ethyl)-3-ethylimidazolium bromide, to prepare photocurable ionic liquid formulations (Fig. 1). Au-NPs (15 nm diameter) were added to our formulations to enhance their conductivities. The results demonstrate that PILs without Au-NPs and PILs with Au-NPs can be readily 3D-printed with commercial 3D UV printers. The inclusion of Au-NPs improved electrical conductivity by many orders of magnitude in the PIL networks. PILs, sculpted into resistor-like shapes using 3D printers and inserted into a circuit, sustained a steady electrical current for several hours. The result suggests that PILs can be used to fabricate functional electronic elements by 3D UV printing.
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| Scheme 1 Synthesis of the monomer (top) and the crosslinker (bottom). Butylated hydroxytoluene (BHT) acts as an inhibitor. | ||
To prepare Au NP-embedded resins, the same procedure as above was followed except that the resin was loaded with an appropriate amount of 15 nm diameter, spherical, dried Au NPs (NanoComposix Inc.). As before, the mixture was shaken in 500 μL Eppendorf tubes for at least 1 hour using a vortex mixer to obtain pale-blue resins, which were then combined for printing.
To print, the substrate was first carefully aligned on the glass build plate, so that the UV projection of the printer was at the center of the O-ring/SecureSeal™ created a reservoir. Next, the file with the desired shape was run on the printer software. A typical printing run was ∼2–5 minutes, depending on the complexity of the structure. The developed structure was washed with ethanol at least three times to remove the uncured resins. The structure was then post-cured in a UV oven (Analytik Jena, AG) for 30 min to ensure full conversion of the print. Structures printed onto FEP were easily removed from the substrate surface. More details on the printing workflow and fidelity assessment in the X- and Y-directions are provided in the SI, S3. Printed examples are given in the SI, S4. Though the Halot Sky model was used in the majority of this work, we tested our formulations with another commercial 3D LCD UV printer (Photon Mono 4, Shenzhen Anycubic Technology Co., Ltd) with similar results (SI, S5).
Out of many possible combinations of ionic liquid monomer and crosslinker formulations, we selected 80 wt% of the synthesized ionic liquid monomer and 20% of the crosslinker monomer mixture dissolved in minimal ethanol, referred to henceforth as 80/20 ionic liquid photocurable formulation, as the photocurable resin for the studies. PILs made from this resin are denoted as 80/20 polymer in the figures. Formulations with crosslinker contents below 20 wt% resulted in structures whose integrity was compromised during the rinsing process after printing. A possible explanation for the need for a high crosslinker concentration (20 wt%) in the resin is that the crosslinker, as explained above, is mainly a solution of starting synthesized ionic liquid monomers, with a small percentage of the actual crosslinker. Increasing the amount of crosslinker resin possibly increases the concentration of the actual crosslinker. To obtain gold nanoparticle (Au-NPs, 15 nm diameter)-embedded PIL composites, resins were prepared by dispersing the Au-NPs via agitation in the above 80/20 ionic liquid photocurable formulation. In this work, we tested 1 wt% of Au-NPs or 2 wt% of Au-NPs in an 80/20 ionic liquid photocurable formulation for 3D UV-printed PIL composites. In all the formulations, ethanol was used as a diluent to facilitate the solubility of the photoinitiator, TPO. Unlike commercial 3D UV printers, which require at least 50 mL of resin to fill the vat or tank, this work used a spacer as a vat (Fig. 2), which only needed ∼1–2 mL of the prepared resin for 3D printing, vastly reducing the amount of material and the cost required for prototyping with ionic liquids. A drawback was that we were limited to centimeter-scale structures. We note that isopropanol, which is commonly used for washing uncured resins, distorted the printed structures.64 We found 70% w/v ethanol to be the best developing solvent for our prints. An advantage of ethanol as the developing solvent was that we could reuse uncured materials by rotovaping the solvent, thereby minimizing waste. All printed structures were cured in a UV oven after washing. We note that post-curing can also be achieved by heating the 3D prints to 100 °C, but this process often results in bubbles within the matrix. We assume that any uncured resin trapped in the matrix is cured in the post-curing process. A selection of printed products is shown in Fig. 3. More examples of printed products are given in the SI, S4. The printed products exhibited high fidelity in the X and Y directions (see the SI, S3). The height (Z-axis, thickness) of the structures depended on the spacer and the amount of liquid. Typically, the height of the printed structures varied from 0.2 mm to 0.5 mm. The 3D-printed structures were pale brown, soft, and stretchable for the 80/20 ionic liquid photocurable formulation and deep purple for Au-NP-filled PIL composites. Printed structures firmly adhered to glass substrates but could be peeled off of FEP substrates to obtain freestanding structures. Overall, our results indicate that the 80/20 ionic-liquid photocurable formulation and its Au-NP-filled resins are promising candidates for printing centimeter-scale PIL objects with commercial 3D UV printers, using both glass and FEP as substrates.
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| Fig. 3 Collection of 3D UV-printed structures with different formulations. Prints from FEP substrates were free-standing. Optical scales are approximate. | ||
SEM images (Fig. 4) provide insights into the morphology of the 3D prints. The structures of the 80/20 polymer were smooth. EDS analysis clearly showed the presence of bromide (the anion in the photocurable ionic liquids) in the X-ray emission spectrum. SEM images of 1 wt% of Au-NPs in the 80/20 ionic liquid photocurable formulation showed a smooth surface. However, there were also scattered spots of aggregation on the surface. Such clusters, assumed to be Au-NPs, are more prominent in 2 wt% of Au-NPs in the 80/20 mixture (see the SI, S6). UV-Vis analysis supports the presence of Au-NP clusters within the matrix. Our Au-NPs, when dispersed in ethanol, have a single strong UV absorption peak at ∼520 nm due to localized surface plasmon resonance absorption, but when the Au-NPs are embedded in the PIL samples, we find the UV absorption, as seen in Fig. 4, to be red-shifted, broad, and weak (Fig. 4, bottom, right). Such changes are indicative of the agglomeration of NPs, which is not uncommon in Au NPs embedded in a polymer matrix.65,66
The degree of polymerization is an important characteristic that influences material properties. Typically, the degree of polymerization for methacrylate-based resins is determined by infrared spectroscopy by comparing the intensity of the infrared absorption peak at 1637 cm−1 [ν(C
C)] of the unreacted methacrylate groups to the intensity of infrared absorption of different internal standard peaks. However, there are discrepancies in such assessments requiring baseline correction due to absorption artifacts in polymers.67 This study found such artifacts detrimental in our PIL analysis due to featureless background absorption in the 1637 cm−1 region. An alternative, which works for our studies, suggested by Delgado et al.,68 is assessing the signal intensity of the C–O stretch doublet of the methacrylate group approximately at 1300 cm−1 and 1320 cm−1.
The doublet peaks shift to lower wavenumbers upon polymerization. It is clear from Fig. 5, which shows barely any residual signal from the doublet peak, that the polymerization is at or near full conversion. We observe the same high degree of polymerization in all our Au NP-embedded PILs. Example infrared spectra of the other 3D-printed samples are provided in the SI, S8. As our experiments are conducted under ambient conditions, we expect water to be present in the matrix. Indeed, we observe a broad absorption band at ∼3400 cm−1, which is typical of the OH stretching vibration of water in all our PILs. Broadly, the results indicate that our 3D UV printing protocols can achieve a high degree of polymerization with the resins.
Fig. 6 shows the TGA results of PILs prepared from the 80/20 photocurable formulation and those with 1 wt% and 2 wt% Au NP-embedded in the PIL matrix from 90 °C to 800 °C under a nitrogen atmosphere. The PILs were compared with a control, which was printed from 80 wt% of the synthesized ionic liquid monomer and 20 wt% of a commercial non-ionic crosslinker monomer, pentaerythritol tetramethacrylate. We observe that, like parent ionic liquids and other reported PILs,69,70 all our PILs exhibited high thermal stability. As seen in Fig. 6 (top), the PILs had an initial loss (∼10% of weight) upon heating until ∼250 °C, possibly due to loss of humidity (water) in the matrix. Above 250 °C, a rapid onset of mass loss is observed in all cases, indicating depolymerization of the methacrylate group or other widespread degradation events.71,72 However, it is evident from Fig. 6 (top) that the degradation pattern of the control PIL differs from others after ∼250 °C. One reason for the difference may be the low actual crosslinker concentration (<5%) in the PIL matrices. We also observe that, unlike the control, PILs with an ionic liquid crosslinker exhibit two additional degradation events at ∼350 °C and ∼450 °C. The difference may be due to the nature of the water in the matrices. Recall that we have observed evidence of water in all our PILs via infrared spectroscopy. TGA-MS provides insights into the nature of this water in PIL matrices. Analyzing the ion current for m/z 18 amu, as presented in Fig. 6 (bottom), shows only one peak for the control, whereas all others exhibit two peaks. The observation implies that matrices prepared using our synthesized ionic-liquid crosslinker contain two distinct types of bound water: tightly bound and loosely bound. The water that evolves in our TGA-MS experiment at ∼300 °C may indicate tightly bound water molecules in the matrices, possibly due to hydrogen bonding between bromide anions and water molecules. The presence of tightly bound water molecules may be one reason why the thermal degradation patterns of printed polymers using the ionic liquid crosslinker, with or without Au-NPs, differ from those of the control. We note that TG-MS also indicates that our matrices are free of solvents or starting monomers. In short, our PILs are thermally stable, where the presence of the ionic liquid crosslinker changes how the polymers degrade when compared to the commercial non-ionic liquid crosslinker.
The glass transition temperature (Tg) of all the polymers, determined by DSC, was below room temperature (SI, S9). Thus, it is not surprising that our polymers were soft and flexible in the printed state. The PIL obtained from the 80/20 photocurable formulation had a Tg of −23 °C, whereas PILs obtained from 80/20 photocurable formulations of 1 wt% of Au-NPs and 2 wt% of Au-NPs had Tg values of −7.2 °C and −3.5 °C, respectively. An increase in the Tg of Au-NP-embedded PIL composites is possibly due to the restriction of polymer chain mobility due to the presence of nanoparticles.73
The stiffness of the printed materials was assessed using nanoindentation and the results are presented in Fig. 7. Control PILs prepared from 80 wt% of the ionic liquid monomer and 20 wt% of a commercial non-ionic crosslinker monomer, pentaerythritol tetramethacrylate, had the highest modulus of ∼3.2 GPa. It is an order of magnitude higher than that of polymers printed with our 80/20 ionic liquid photocurable formulation (0.46 ± 0.04 GPa). One explanation for this observation is that the commercial crosslinker has four methacrylate groups, whereas our synthesized ionic liquid-based crosslinker contains only two photocurable groups. The large difference may also arise from a lower effective crosslink density in the PILs than in the control. Although both PILs and the control were prepared using 20 wt% of the crosslinker in the formulation, in reality, the ionic liquid crosslinker is a dilute solution (<5%) of the actual crosslinker(s) in the ionic liquid monomer. The presence of tightly bound water, as observed in our TGA-MS experiments on PILs, may also contribute to the observed trends in tensile strength. Water absorbed into a polymer matrix can act as a plasticizer, disrupting intermolecular forces between polymer chains. Such disruption can significantly reduce tensile strength. Apart from the difference between PILs and the control, there are differences among PILs. The Young's modulus of structures with 1 wt% of Au NPs in an 80/20 ionic liquid photocurable formulation was 0.34 ± 0.04 GPa, slightly higher than its 2% counterpart, which was 0.28 ± 0.03 GPa. We assume that increased agglomeration with higher Au-NP concentrations creates localized weak points in the composite, thereby reducing the tensile strength.
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| Fig. 7 Modulus of PILs measured by nanoindentation. The control is a PIL with the commercial non-ionic crosslinker pentaerythritol tetramethacrylate. | ||
To test the potential application in electronics, we measured the conductivity of printed circular PIL films (thickness ∼0.5 mm) using a four-point probe method. Our instrument uses a direct current voltage and measures the current across the sample to calculate conductivity. It is relevant to electronics for initial assessment, as most electronic devices operate on direct current. Again, as a control, we used 80 wt% of the ionic liquid monomer and 20 wt% of a commercial non-ionic crosslinker monomer, pentaerythritol tetramethacrylate. The conductivity of the control films was below the detectability limit of our four-point probe instrument. In other words, no conductivity was detected for printed films with our control formulation. On the other hand, printed films of the 80/20 ionic liquid photocurable formulation consistently exhibited a conductivity of approximately 10−6 S cm−1 (Fig. 8, 80/20 polymer). The measured conductivity is consistent with other reports.38 It supports our earlier assumption that an ionic liquid-based crosslinker in PIL matrices increases ion densities, enabling improved conductivity. However, it is pertinent to note that our crosslinker is a dilute solution in the monomer, as mentioned earlier, which may result in lower-than-expected ion densities in the cured networks, reducing ion conductivity. Upon introducing Au-NPs into the ionic liquid resins, the conductivity of the printed PIL further increased from 10−6 S cm−1 to 10−4 S cm−1. The two-order-of-magnitude increase in conductivity may be attributable to additional electronic pathways and the high surface area of the Au nanoparticles, in addition to the intrinsic ion-transport mechanism within PILs.54,55 However, the exact mechanism of enhancement requires further investigation with tools such as electrochemical impedance spectroscopy to determine the contributions of electronic and ionic processes in the system.53,74 It is also possible that bound water, which we observed in thermal studies and infrared spectra, may play a role in conduction, which requires further study. Regardless of the mechanism, materials with conductivity in the range of 10−4 S cm−1 are attractive for use in flexible electronics. The trend shown in Fig. 8 indicates a trade-off between increased Au-NP concentration and observed conductivity in the resin, consistent with observations reported elsewhere, in which the aggregation of NPs at higher concentrations is suggested to result in poor bulk properties of polymer–nanoparticle composites.75,76 Overall, our studies show that structures prepared from 1 wt% of Au-NPs in the 80/20 ionic liquid photocurable formulation were best in terms of both printing and conductivity.
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| Fig. 8 Conductivity of PILs measured using a four-point station. The control is a PIL with the commercial non-ionic crosslinker pentaerythritol tetramethacrylate. | ||
In order to validate whether 1 wt% of Au-NPs in the 80/20 photocurable formulation can be used as the construction material for a functional element in a circuit, we designed and 3D-printed a centimeter-scale structure in the shape of a resistor (∼1 cm (l) × 1 cm (w) × 200 mm (h)) with a connector pad (∼0.2 cm (l) × 0.2 cm (w) × 500 μm (h)) on a microscope glass slide using the same method as described earlier. The design serves as a proof of concept, showing that functional elements can be built using our ionic liquid formulation. Fig. 9 (top, left) is a representative of one such device. The same design on FEP substrates to obtain free-standing 3D-printed resistors was found to be mechanically weak, so our studies were confined to resistors printed on glass substrates. In our scheme, as shown in the circuit diagram in Fig. 9 (bottom left), the printed resistor was incorporated into an electrical circuit and tested under ambient conditions (see the SI, S10, for more details). Current flowing through the circuit was used as the metric for assessing the functionality of the printed resistor. Our results were qualitative but indicated that applying a 30 V direct current power supply produced a detectable current in the microampere range through the circuit. Fig. 9 (top, right) shows current responses from a circuit, with a printed resistor, undergoing turn-on and turn-off cycles separated by a 24-hour gap. Turning off the circuit with the printed resistor for 24 hours and restarting it again for 2 hours showed that the current was within 5% of the original value. Encouraged by the results, we independently printed and tested eight additional resistors using the design described above. The measured currents were between 23 mA and 18 mA from the printed resistors (Fig. 9 (bottom, right)). The current in each circuit remained stable for two hours of continuous operation, with minimal deviation from the mean. Using the measured current as a quality control metric, the coefficient of variability was about 5.8% among devices. Given that the devices were made from different batches of starting materials, the low coefficient of variability not only demonstrates reproducibility but also suggests batch-to-batch consistency and the robustness of our printing protocols. One limitation observed was that the continuous operation of the circuit for more than 5 hours resulted in a 20% loss of the magnitude of the current flowing through the circuit. This may be due to heating effects that may have resulted in polymer degradation. We also observed yellowing77 of the polymer at the contact points of the resistor with the circuit. This phenomenon was observed irrespective of whether the contact material to the PIL resistor was copper or nichrome wires. Often, wire-to-pad disconnection was the main cause of failure in extended operation. Overall, our results demonstrate that 3D-printed PIL structures are stable against the flow of electrical current for a short duration. We envisage that our concept validation will inspire others to use our formulations to prepare user-defined structures for a specific task (e.g., CO2 sensing) for integration into a working circuit.
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