Engineering polymers are critical for contemporary high-performance applications where toughness, thermal stability, and density are at a premium. These materials often demand high-energy processing conditions or highly reactive monomers that hold negative impacts on human and environmental health. Thus, this work serves to remediate the negative impacts of engineering polymer synthesis by addressing toxicity and processing at the monomer level, while maintaining or exceeding previous thermomechanical and stimuli-responsive performance. Polyurethanes (PUs) represent a class of engineering polymers that possess highly modular properties due to the diverse monomer selection available for their synthesis. The efficient reaction between isocyanates and hydroxyls impart stellar properties and flexible processing modalities, however recent scrutiny regarding the toxicity of the isocyanate precursors has driven the search for non-isocyanate polyurethane (NIPU) pathways. The advancement of bis-carbonylimidazolide (BCI) monomers for the synthesis of NIPU thermoplastics and foams is thoroughly investigated in this work. Remarkably, a novel decarboxylation pathway for BCI monomers controlled by catalyst loading enabled in-situ CO2 generation during crosslinking with trifunctional amines, and resulted in a facile synthetic route for NIPU foams. Further explorations into catalyst considerations revealed Dabco® 33-LV as a suitable mechanism for controlling reaction times and careful selection of surfactant concentration provided control over pore size and geometry. This led to a library of flexible and rigid NIPU foams that displayed a wide range of thermomechanical properties. Furthermore, sequestration of the imidazole byproduct through an efficient Michael reaction identified maleimide and acrylate additives as a viable pathway to eliminate post-processing steps resulting in NIPU foam synthesis that is amenable to current industrial standards. This route held advantages over the isocyanate route, as condensate removal drove molecular weight increase and ultimately achieved the first reported phase separation behavior of a NIPU thermoplastic containing a poly(ethylene glycol) soft segment. Furthermore, sustainable considerations for engineering polymers were explored with the introduction of a novel cyclobutane bisimide monomer that readily installs into various polymeric systems. Direct installation of this monomer, CBDA-AP-I, into a polysulfone backbone enabled controlled photo-cleavage, while further hydroxy ethyl functionalization allowed for incorporation into PU systems for photo-cleavable high-performance adhesive applications.

Both molecular structure of macromolecular materials and subsequent processing of these materials dictate resulting material properties. In this work novel synthetic strategies combined with detailed analytical methodology reveal fundamental structure-processing-property relationships in thermoplastic polyesters, thermoplastic polyurethanes, covalently crosslinked acetal functionalized networks, and small molecule surfactants. 4,4’ dimethyloxybisbenzoate afforded a series of novel polyester structures, and the incorporation of this monomer both increased the Tg and decreased the crystallinity in cyclohexane dimethanol based polyesters. Solubility and dynamic light scattering experiments combined with oscillatory rheology techniques provided methodology to validate polyurethane extrusion in commercial polyurethanes. Acid catalyzed hydroxyl addition to vinyl ethers provided two families of acetal functionalized poly(ethylene glycol hydrogels). Stoichiometric control of binary thiol-acrylate polymerizations afforded hydrogels with both tunable mechanical properties and predictable degradation profiles. Following this work, a photoacid generator catalyzed cationic catalysis provided acetal functionalized organogels whose mechanical properties were predicted by excess vinyl ether monomers which underwent cationic polymerization under the same reaction conditions that yielded acetal functionalization. Time resolved FT-IR spectroscopy provided new understanding in hydroxyl vinyl ether reactions, where both hydroxyl addition to a vinyl ether and vinyl ether cationic polymerization occur concurrently. This work inspired research into new reactive systems for photobase generator applications. However, current photobase generator technologies proved incompatible for carbon-Michael reactions between acetoacetate and acrylate functionalities as a result of uncontrollable acrylate free radical polymerization. The fundamental knowledge and synthetic strategies afforded by these investigations were applied to small molecule surfactant systems for fire-fighting applications. Triethylsilyl-containing zwitterionic and cationic surfactants displayed surface tensions lower than hydrocarbon surfactants, but larger than siloxane-containing surfactants. For the first time, oscillatory rheology and polarized optical light imagine rheology highlighted shear-induced micelle alignment in triethylsilyl surfactants, which provided more stable foams than zwitterionic analogues. The knowledge gained from these investigations provided fundamental structure-processing-property relationships in small molecule surfactant solutions applied as fire-fighting foams. This discovery regarding the effect of self-assembled structures in foam solutions informs the design and analysis of next generation surfactants to replace fluorocarbon surfactants in fire-fighting foam applications.

High-performance polymers (HPPs) have dominated the synthetic polymer market for critical applications, including aerospace, energy, microelectronic, and transportation industries since their development in the mid-1900s. Although their structures share general similarities, such as high aromatic content, HPPs offer wide structural variance providing amorphous and semi-crystalline systems. As a result, conventional processing methods employed for HPPs are energy intensive and accessible part geometry is limited; often requiring subsequent subtractive techniques, i.e.,; milling, to obtain high quality and performant parts. Traditional processes were challenged by the emergence of advanced manufacturing techniques, such as 3D printing, which spurred significant academic and industrial interest. In the first project, poly(arylene ether sulfone)s (PSU) were chemically modified post-polymerization to enable ensuing photopolymerization of high molecular weight (Mn) PSU solutions into complex shapes with vat photopolymerization (VP). The resulting materials exhibited fast crosslinking, but low and unstable plateau storage moduli (G’). To overcome this, addition of low molecular weight crosslinker and precise control of UV irradiation increased crosslink density and inhibited photodegradation events, respectively. Ultimately, these modifications facilitated the first report of PSU structures fabricated with a UV-assisted AM modality. Next, 3D printable polyimides (PIs) were synthesized and extensively characterized to further expand the HPP AM toolbox. However, fully aromatic PIs pose a significant challenge as most are insoluble, intractable, and lack any discernable viscous flow. AM PIs were produced using two distinct approaches previously reported in the Long research group; the pendant salt approach imparts photoreactivity through the neutralization of the poly(amic acid) intermediate with small molecule amino-acrylates while the polysalt approach employs dicarboxylate-diammonium ionic organization to template the PI amongst an acrylic scaffold. Through the pendant salt approach, water soluble PI precursors enabled facile AM of complex structures, which served as efficient carbon precursors. The polysalt approach offers superior solid content and solution viscosities; however, these highly polar solutions initially exhibited deleterious side reactions. Application of acid-base fundamentals provided novel printable polysalt solutions with extended shelf-life, reproducible printing, and simplified processing. The relationships established from these projects expanded the applications of the most performant synthetic polymers and will inform future polymer design for additive manufacturing.

Creating 3D objects out of high performance polymers, such as polyimides, is notoriously difficult since the highly stable polymer backbone limits processibility without extreme conditions. However, designing the polyimide precursor to crosslink upon photoirradiation enables the additive manufacturing of polyimides into complex, 3D objects. Crosslinking the photoactive polyimide precursor forms a solid 3D organogel, then subsequent thermal treatment removes the sacrificial scaffold and simultaneously imidizes the precursor into a 3D polyimide. The collaborative efforts of the Long and Williams group at Virginia Tech created three chemically distinct photoactive polyimide precursors to additively manufacture 3D polyimide objects for aerospace applications and to maintain the nuclear stockpile. The first chapter of this dissertation introduces fully aromatic polyimides and the additive manufacturing techniques used to print photoactive polyimide precursors. The second chapter reviews the common pore forming methods typically utilized to develop porous polyimides for low dielectric applications. The following chapters investigate the impact of the sacrificial scaffold on the thermo-oxidative aging behavior of the polyimide precursors after imidization, then focuses on lowering the imidization temperature of the polyimide precursor using base catalysis. These investigations lead to the creation of photoactive polysalts with polyethylene glycol (PEG) side chains to develop 3D, porous polyimides with tunable morphologies. Varying the molecular weight and concentration of the PEG side chains along the backbone tuned the pore size, and the photoactive nature of the polyimide precursor enabled 3D, porous polyimides printed using digital light processing.

The excessive use of fossil fuels over the last few centuries has led to unprecedented changes in climate and a steady increase in the average surface global temperatures. Direct Air Capture(DAC) aims to capture CO2 directly from the atmosphere and alleviate some of the adverse effects of climate change. This dissertation focuses on methodologies to make advanced functional materials that show good potential to be used as DAC sorbents. Details on sorbent material synthesis and post-synthesis methods to obtain high surface area morphologies are described in detail. First, by incorporating K2CO3 into activated carbon (AC) fiber felts, the sorption kinetics was significantly improved by increasing the surface area of K2CO3 in contact with air. The AC-K2CO3 fiber composite felts are flexible, cheap, easy to manufacture, chemically stable, and show excellent DAC capacity and (de)sorption rates, with stable performance up to ten cycles. The best composite felts collected an average of 478 µmol of CO2 per gram of composite during 4 h of exposure to ambient (24% RH) air that had a CO2 concentration of 400-450 ppm over 10 cycles. Secondly, incorporating the amino acid L-arginine (L-Arg) into a poly(vinyl alcohol) (PVA) nanofiber support structure, created porous substrates with very high surface areas of L-Arg available for CO2 sorption. The bio-inspired PVA-Arg nanofiber composites are flexible and show excellent DAC performance compared to bulk L-Arg. The nanofiber composites are fabricated from an electrospinning process using an aqueous polymer solution. High ambient humidity levels improve sorption performance significantly. The best performing nanofiber composite collected 542 µmol of CO2 per gram of composite during 2 h of exposure to ambient, high humidity (100% RH) air that had a CO2 concentration of 400-450 ppm. Finally, poly(vinyl guanidine) (PVG) polymer was synthesized and tested for sorption performance. The fabrication of PVG nanofibers, divinyl benzene crosslinked PVG beads and glutaraldehyde crosslinked PVG were demonstrated. The sorption performance of the fabricated sorbents were tested with the glutaraldehyde crosslinked PVG having a dynamic sorption capacity of over 1 mmol of CO2 per gram of polymer in 3 h. The sorption capability of liquid PVG was also explored.

Lignin is a naturally abundant source of aromatic carbon but is largely underutilized inindustry because it is difficult to decompose. Recent research activity has targeted the development of a biological platform for the conversion of lignin and lignin-derived feedstock. Corynebacterium glutamicum is a standout candidate for the bacterial depolymerization and assimilation of lignin because of its performance as an industrial producer of amino acids, resistance to aromatic compounds in lignin, and low extracellular protease activity. Under the current study, nine experimental strains of C. glutamicum were engineered with sequencing-confirmed plasmids to overexpress and secrete lignin-modifying enzymes with the eventual goal of using lignin as raw feed for the sustainable production of valuable chemicals. Within the study, laccase and peroxidase activity were discovered to be decreased in C. glutamicum culture media. For laccase the decrease reached statistical significance, with an activity of about 10.9 U/L observed in water but only about 7.56 U/L and 7.42 U/L in fresh and spent BHI media, respectively, despite the same amounts of enzyme being added. Hypothesized reasons for this inhibitory effect are discussed here, but further work is needed to identify causative factors and realize the potential of C. glutamicum for waste biomass valorization.