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Mechanically-induced redox processes offer a promising alternative to more conventional thermal and photochemical synthetic methods. For macromolecule synthesis, current methods utilize sensitive transition metal additives and suffer from background reactivity. Alternative methodology will offer exquisite control over these stimuli-induced mechanoredox reactions to couple force with redox-driven chemical transformations. Herein, we present the iodonium-initiated free-radical polymerization of (meth)acrylate monomers under ultrasonic irradiation and ball-milling conditions. We explore the kinetic and structural consequences of these complementary mechanical inputs to access high molecular weight polymers. This methodology will undoubtedly find broad utility across stimuli-controlled polymerization reactions and adaptive material design. 

Polymer molecular weight, or chain length distributions, are a core characteristic of a polymer system, with the distribution being intimately tied to the properties and performance of the polymer material. A model is developed for the ideal distribution of polymers made using reversible activation/deactivation of chain ends, with monomer added to the active form of the chain end. The ideal distribution focuses on living chains, with the system having minimal impact from irreversible termination or transfer. This model was applied to ATRP, RAFT, and cationic polymerizations, and was also used to describe complex systems such as blended polymers and block copolymers. The model can easily and accurately be fitted to molecular weight distributions, giving information on the ratio of propagation to deactivation, as well as the mean number of times a chain is activated/deactivated under the polymerization conditions. The mean number of activation cycles per chain is otherwise difficult to assess from conversion data or molecular weight distributions. Since this model can be applied to wide range of polymerizations, giving useful information on the underlying polymerization process, it can be used to give fundamental insights into macromolecular synthesis and reaction outcomes. 

Dynamic covalent Diels–Alder chemistry was combined with multiwalled carbon nanotube (CNT) reinforcement to develop strong, tough and conductive dynamic materials. Unlike other approaches to functionalizing CNTs, this approach uses Diels–Alder bonds between diene pendant groups on the polymer and the CNT surface πσ bonds acting as dienophiles. Experimental and simulation data align with the CNT reinforcement coming from dynamic covalent bonds between the matrix and the CNT surface. The addition of just 0.9 wt% CNTs can lead to an almost 3-fold increase in strength and 6–7 order of magnitude increases in electrical conductivity, and materials with 0.45 wt% CNTs show excellent strength, self-healing and conductivity.