Flow Synthesis of Conjugated Polymers: Advances, Challenges, Instrumentation, and Future Directions

Continuous flow synthesis is increasingly recognized as a valuable tool for simpler and scalable production of conjugated polymers. Compared to traditional batch processes, which often suffer from batch-to-batch variation, downtime, and multistep procedures, flow synthesis offers better control over reaction conditions, improved reproducibility, and possibly enhanced sustainability. These advantages make flow chemistry a promising approach for addressing some of the long-standing challenges in conjugated polymer synthesis. In this review, we highlight developments in the field and detail the range of polymer structures accessible under continuous flow conditions. Special attention is given to the comparison of batch and flow approaches, the impact of flow synthetic processes on polymer degradation, and emerging strategies for the synthetic adaptation in flow systems. As the use of continuous flow for conjugated polymer synthesis remains relatively limited, the review also provides a summary of dedicated flow systems available, highlighting opportunities and challenges for integrating continuous flow into mainstream and industrial polymer science.

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