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Silver nanoparticles (AgNP) are widely exploited for their effective antimicrobial activity against a range of pathogens. Their high efficacy in this regard has seen the global demand for AgNP in consumer products steadily increase in recent years, necessitating research into novel low environmental impact synthesis approaches. Here we present a new synthetic methodology to produce polymer-AgNP composite microparticles using supercritical carbon dioxide (scCO 2) and avoiding use of any petrochemically derived solvents. Poly(methyl methacrylate)-poly(4-vinylpyridine) (PMMA-b-P4VP) block copolymers were synthesised via RAFT-mediated dispersion polymerisation in scCO 2, with in situ thermal degradation of various amounts of a CO 2-soluble silver complex. Selective interaction of the silver with the pyridinyl moieties of the block copolymer allowed the formation of AgNP, dispersed within the block copolymer microparticles, leading to homogeneous composites. The by-products of the reaction were also removed by extracting with a flow of CO 2 to yield a clean dry product in a single process. The composites were found to be non-cytotoxic and proved to have good antimicrobial activity against two bacterial strains. Though no significant activity was seen for at least the first 24 hours, inhibition of bacterial growth afterwards proved to be extremely persistent, with inhibition observed even after 15 days. Finally, the microparticulate nature of the synthesised composites was exploited and tested for compatibility in the Laser Sintering (LS) 3D printing process. Composite microparticles were fused to produce solid objects, without aggregation of the AgNP. With further optimisation, these composites could prove to be an incredibly versatile ‘ink’ that may be used within additive manufacturing and 3D printing to rapidly produce bespoke medical devices with inherent antimicrobial activity.

The dispersion polymerisation of methyl methacrylate (MMA) is a widely employed method for producing discrete, spherical PMMA particles from traditional solvents, which cover a broad particle size range. With environmental impact becoming an ever more widespread concern, there is increasing demand for greener solvents with advantageous characteristics. Supercritical carbon dioxide (scCO2) offers the potential of a greener solvent for dispersion polymerisations, with uniquely tuneable solvent properties and the ability to avoid energy and cost intensive drying steps. In this work, the tuneable density of scCO2 was exploited to influence the solubility of poly(dimethyl siloxane) stabilisers in the dispersion polymerisation of methyl methacrylate as a proof-of-concept. By varying the reactor pressure at the start of polymerisation, the final particle size was altered, without the need for cosolvent systems used in traditional solvents. Finally, this additional particle size control mechanism was exploited to achieve a PMMA particle size range far beyond what was previously attainable with this stabiliser. Thus, further enhancing the potential use of scCO2 as a green solvent for industrial polymer production.

Epoxidized oils are commonly used in the plastics industry as additives in the formulation of polyvinyl chloride (PVC) and as monomers in the coating industry. They are produced from petrochemical feedstocks or by chemical epoxidation of natural oils. Currently, the synthesis processes of these materials are expensive, utilize volatile organic solvents and hazardous oxidants, which are unfavorable for the environment. There is a need to find natural epoxidized oils. Vernonia galamensis (ironweed) is a plant found in abundance in Ethiopia with no commercial value, but its seeds contain 40 wt% epoxide rich triglycerides. V. galamensis oil contains up to 80 wt% of vernolic acid (VA), a mono-unsaturated fatty acid with an additional epoxide functionality. The presence of alkene and epoxide(oxirane) groups offers excellent opportunities to synthesize new building blocks for polymerisations. Here, we report a green and efficient extraction methodology (up to 80% of extraction-efficiency) of the triglyceride vernonia oil from V. galamensis using supercritical carbon dioxide (scCO 2). We then report the synthesis of a series of polymerisable monomers (conversion in monomers 64%–99%) based on the VA obtained from the saponification process. Finally, the novel monomers are polymerized into different polymers through polycondensation using a mixture of metal-based and enzyme catalysts.

Enzymatically synthesised poly(glycerol adipate) (PGA) has shown a palette of key desirable properties required for a biomaterial to be considered a ‘versatile polymeric tool’ in the field of drug delivery. PGA and its variations can self-assemble into nanoparticles (NPs) and interact at different levels with small active molecules. PGA derivatives are usually obtained by functionalising the glyceryl side hydroxyl group present along the main polymer scaffold. However, if the synthetic pathways are not finely tuned, the self-assembling ability of these new polymeric modifications might be hampered by the poor amphiphilic balance. For this reason, we have designed a straightforward one-pot synthetic modification, using a small library of diols in combination with glycerol, aimed at altering the backbone of the polymer without affecting the hydrophilic glyceryl portion. The diols introduce additional functionality into the backbone of PGA alongside the secondary hydroxyl group already present. We have investigated how extra functionalities along the polymer backbone alter the final polymer reactivity as well the chemical and biological properties of the nanoparticles. In addition, with the intent to further improve the green credentials of the enzymatic synthesis, a solvent derived from renewable resources, (2-methyl tetrahydrofuran, 2-MeTHF) was employed for the synthesis of all the PGA-variants as a replacement for the more traditionally used and fossil-based tetrahydrofuran (THF). In vitro assays carried out to evaluate the potential of these novel materials for drug delivery applications demonstrated very low cytotoxicity characteristic against NIH 3T3 model cell line.