This manuscript describes
the versatility of highly directional, noncovalent interactions, i.e.,
quadruple hydrogen bonding (QHB), to afford novel polyurea segmented
supramolecular polymers for melt extrusion three-dimensional (3D)
printing processes. The molecular design of the polyurea elastomers
features (1) flexible polyether segments and relatively weak urea
hydrogen-bonding sites in the soft segments to provide elasticity
and toughness, and (2) strong ureido-cytosine (UCyt) QHB in the hard
segments to impart enhanced mechanical integrity. The resulting polyureas
were readily compression-molded into mechanically-robust, transparent,
and creasable films. Optimization of polyurea composition offered
a rare combination of high tensile strength (95 MPa), tensile elongation
(788% strain), and toughness (94 MJ/m3), which are superior
to a commercially available Ninjaflex elastomer. The incorporation
of QHB facilitated melt processability, where hydrogen bonding dissociation
provided low viscosities at printing temperatures. During cooling,
directional self-assembly of UCyt QHB facilitated the solidification
process and contributed to part fidelity with the formation of a robust
physical network. The printed objects displayed high layer fidelity,
smooth surfaces, minimal warpage, and complex geometries. The presence
of highly directional QHB effectively diminished mechanical anisotropy,
and the printed samples exhibited comparable Young’s moduli
along (x–y direction, 0°)
and perpendicular to (z-direction, 90°) the
layer direction. Remarkably, the printed samples exhibited ultimate
tensile strains approaching 500% in the z-direction
prior to failure, which was indicative of improved interlayer adhesion.
Thus, this design paradigm, which is demonstrated for novel polyurea
copolymers, suggests the potential of supramolecular polymers with
enhanced mechanical performance, melt processability, recyclability,
and improved interlayer adhesion for melt extrusion additive manufacturing
processes.