Architectural differences in photopolymerized PEG-based thiol-acrylate hydrogels enable enhanced mechanical properties and 3D printability

Hydrogels have been widely investigated for applications in the human body due to their tunability and biocompatibility. Nevertheless, their application is still limited by their relatively low mechanical strength relative to load-bearing tissue scaffolds like articular cartilage. In this work, we synthesized hydrogels by combining linear poly(ethylene glycol) dimethacrylate (PEGDMA) with a 3-arm-PEG end-functionalized with thiol. We demonstrate that the combination of thiol-ene click chemistry with a multifunctional crosslinker reduces the crosslink and entanglement density in comparison with the otherwise statistically crosslinked/polymerized PEGDMA, whereby the only viable mode of gelation is through radical propagation or termination at the double bond. The corresponding minimization of topological heterogeneities that arises during thiol-ene crosslinking results in hydrogels with compressive strength in the range of tens of MPa. The molar mass of the linear PEGDMA precursor is readily tunable, unlocking access to a wider range of mechanical properties. We employed photo-mediated crosslinking protocol, which is amenable to advanced processing technologies such as light-based 3D printing techniques. Such advanced fabrication processes offer high precision and control during the generation of customizable macroscopic objects. Simple prototypes were generated using digital light processing (DLP) equipment. We demonstrate that integrating a simple co-macromonomer into a widely employed hydrogel platform can unlock new mechanical regimes and mitigate the inherent brittleness associated with these materials. The simplicity of this approach, coupled with its easy tunability and adaptability to light-based techniques, holds promise for broadening hydrogel applications in tissue engineering. Our findings contribute to advancing materials and methodologies, facilitating enhanced design and fabrication of functional constructs.