Three‐dimensional chemical reactors: in situ materials synthesis to advance vat photopolymerization

3D Patterning of Perovskite Quantum Dots via Direct In Situ Femtosecond Laser Writing

Perovskite quantum dots (PQDs) exhibit remarkable optical properties, making them highly promising for next-generation display technologies. However, achieving precise PQDs patterning is hindered by significant challenges, including the inability to achieve true three-dimensional (3D) structuring and the risk of damaging the delicate perovskite crystal lattice. Existing methods struggle to achieve true 3D structuring while preserving the optical integrity. This study introduces an in situ patterning technique using direct laser writing (DLW). By leveraging the nonlinear absorption properties of femtosecond lasers, thiol-Ene photopolymerization is triggered, transforming perovskite precursors into complex fluorescent structures. Unlike conventional methods, this precursor-based approach minimizes laser power requirements and prevents quantum dot degradation caused by high-energy exposure. It enables precise, scalable fabrication while maintaining the structural and optical stabilities of PQDs. This innovation provides a robust platform for developing advanced display technologies, optoelectronic devices, and miniaturized on-chip systems, paving the way for future high-performance applications.

Additive manufacturing of hollow connected networks for solar photo-Fenton-like catalysis

A 3D-printing approach is used to fabricate green bodies/precursor microarchitectures that, upon annealing, allow the fabrication of hierarchical 3D hollow microarchitectures (3DHMs). The 3DHMs are composed mainly of TiO2 and inorganic stabilizers that enable the production of inorganic cellular units upon thermal annealing at 650 °C. Morphological inspection reveals that the 3D architecture beams comprise TiO2 nanoparticles (NPs). The inner and outer diameters of the hollow beams are ∼80 μm and ∼150 μm, retained throughout the 3D hollow network. A proof-of-concept photo-Fenton reaction is assessed. The 3DHMs are impregnated with α-Fe2O3 NPs to evaluate solar photo-Fenton degradation of organic compounds, such as MB used as control and acetaminophen, an organic pollutant. The optical, structural, and chemical environment characteristics, alongside scavenger analysis, generate insights into the proposed solar photo-Fenton degradation reaction over TiO2 3DHMs loaded with α-Fe2O3. Our work demonstrates newly hollow printed microarchitecture with interconnected networks, which can help direct catalytic reactions.

Growing three-dimensional objects with light

Vat photopolymerization (VP) additive manufacturing enables fabrication of complex 3D objects by using light to selectively cure a liquid resin. Developed in the 1980s, this technique initially had few practical applications due to limitations in print speed and final part material properties. In the four decades since the inception of VP, the field has matured substantially due to simultaneous advances in light delivery, interface design, and materials chemistry. Today, VP materials are used in a variety of practical applications and are produced at industrial scale. In this perspective, we trace the developments that enabled this printing revolution by focusing on the enabling themes of light, interfaces, and materials. We focus on these fundamentals as they relate to continuous liquid interface production (CLIP), but provide context for the broader VP field. We identify the fundamental physics of the printing process and the key breakthroughs that have enabled faster and higher-resolution printing, as well as production of better materials. We show examples of how in situ print process monitoring methods such as optical coherence tomography can drastically improve our understanding of the print process. Finally, we highlight areas of recent development such as multimaterial printing and inorganic material printing that represent the next frontiers in VP methods.

Two-Orders-of-Magnitude Enhancement of Photoinitiation Activity via a Simple Surface Engineering of Metal Nanoclusters

Development of high-performance photoinitiator is the key to enhance the printing speed, structure resolution and product quality in 3D laser printing. Here, to improve the printing efficiency of 3D laser nanoprinting, we investigate the underlying photochemistry of gold and silver nanocluster initiators under multiphoton laser excitation. Experimental results and DFT calculations reveal the high cleavage probability of the surface S-C bonds in gold and silver nanoclusters which generate multiple radicals. Based on this understanding, we design several alkyl-thiolated gold nanoclusters and achieve a more than two-orders-of-magnitude enhancement of photoinitiation activity, as well as a significant improvement in printing resolution and fabrication window. Overall, this work for the first time unveils the detailed radical formation pathways of gold and silver nanoclusters under multiphoton activation and substantially improves their photoinitiation sensitivity via surface engineering, which pushes the limit of the printing efficiency of 3D laser lithography.

On-Demand 3D Spatial Distribution of Magnetic Permeability Based on Fe3 O4 Nanoparticle Liquid Toward Micro-Cavity Detectors

The change of 3D spatial distribution of magnetic permeability can lead to the generation of introduced electrical signals. However, present studies can only achieve rough regulation by simple shape deformation of magnetic elastomers such as compression, bending, or stretching. Accurate control of the 3D spatial distribution of magnetic permeability is still an open question. In this study, an on-demand 3D spatial distribution of magnetic permeability by controlled flowing of Fe3 O4 nanoparticle liquid (FNL) is demonstrated. The flowing routes of FNL are tuned by a 3D-printed cage with pre-designed hollow structure, thus changing the 3D spatial distribution of magnetic permeability. Then, eight symmetrically distributed coils under cage are used to receive characteristic induction voltage signals. Maxwell numerical simulation reveals the working mechanism of signal generation. Notably, those eight coils can detect FNL flowing status in eight directions, allowing recognition of up to 255 different FNL flowing combinations. By introducing machine learning, the micro-cavity detector based on FNL can distinguish nine kinds of micro-cavity structures with an accuracy of 98.77%. This work provides a new strategy for the adjustment of the 3D spatial distribution of the magnetic permeability and expands the application of FNL in the field of space exploration.

Hierarchically Structured Metal-Organic Framework Polymer Composites for Chemical Warfare Agent Degradation

Metal-organic frameworks (MOFs) have captured the imagination of researchers for their highly tunable properties and many potential applications, including as catalysts for a variety of transformations. Even though MOFs possess significant potential, the challenges associated with processing of these crystalline powders into usable form factors while retaining their functional properties limit their end use applications. Herein, we introduce a new approach to construct MOF-polymer composites via 3D photoprinting to overcome these limitations. We designed photoresin composite formulations that use polymerization-induced phase separation to cause the MOF catalysts to migrate to the surface of the printed material, where they are accessible to substrates such as chemical warfare agents. Using our approach, MOF-polymer composites can be fabricated into nearly any shape or architecture while retaining both the excellent catalytic activity at 10 wt % loading of the MOF components and the flexible, elastomeric mechanical properties of a polymer.

3D printing of inorganic nanomaterials by photochemically bonding colloidal nanocrystals

3D printing of inorganic materials with nanoscale resolution offers a different materials processing pathway to explore devices with emergent functionalities. However, existing technologies typically involve photocurable resins that reduce material purity and degrade properties. We develop a general strategy for laser direct printing of inorganic nanomaterials, as exemplified by more than 10 semiconductors, metal oxides, metals, and their mixtures. Colloidal nanocrystals are used as building blocks and photochemically bonded through their native ligands. Without resins, this bonding process produces arbitrary three-dimensional (3D) structures with a large inorganic mass fraction (~90%) and high mechanical strength. The printed materials preserve the intrinsic properties of constituent nanocrystals and create structure-dictated functionalities, such as the broadband chiroptical responses with an anisotropic factor of ~0.24 for semiconducting cadmium chalcogenide nanohelical arrays.

Carbon Additive Manufacturing with a Near-Replica "Green-to-Brown" Transformation

Nanocomposites containing nanoscale materials offer exciting opportunities to encode nanoscale features into macroscale dimensions, which produces unprecedented impact in material design and application. However, conventional methods cannot process nanocomposites with a high particle loading, as well as nanocomposites with the ability to be tailored at multiple scales. A composite architected mesoscale process strategy that brings particle loading nanoscale materials combined with multiscale features including nanoscale manipulation, mesoscale architecture, and macroscale formation to create spatially programmed nanocomposites with high particle loading and multiscale tailorability is reported. The process features a low-shrinking (<10%) "green-to-brown" transformation, making a near-geometric replica of the 3D design to produce a "brown" part with full nanomaterials to allow further matrix infill. This demonstration includes additively manufactured carbon nanocomposites containing carbon nanotubes (CNTs) and thermoset epoxy, leading to multiscale CNTs tailorability, performance improvement, and 3D complex geometry feasibility. The process can produce nanomaterial-assembled architectures with 3D geometry and multiscale features and can incorporate a wide range of matrix materials, such as polymers, metals, and ceramics, to fabricate nanocomposites for new device structures and applications.

Ethylene-Vinyl Acetate Copolymers as Potential Thermoplastic Modifiers of Photopolymer Compositions

The possibility of using thermoplastic polymers in photopolymer compositions for SLA and DLP is discussed in this article. The diffusion and mutual solubility of uncured systems based on tert-butyl acrylate (tBA) and ethylene-vinyl acetate copolymers (EVA) or low-density polyethylene (LDPE) were studied. The solubility and diffusion of tBA with EVA containing 7, 20, and 40 wt.% vinyl acetate (VA) and with LDPE in the temperature range 20-75 °C were studied by optical micro-interferometry method. Phase diagrams of LDPE-tBA, EVA-7-tBA, and EVA-20-tBA systems were obtained. It is shown that the compositions are characterized by the phase-state diagrams of amorphous separation with the upper critical solution temperature (UCST). The concentration dependences of the interdiffusion coefficients as well as dependences of the self-diffusion coefficients on VA content and on temperature were plotted. The activation energy of self-diffusion of EVA and LDPE was calculated. It was shown that the most promising tBA modifier is EVA-40, which is completely soluble at all studied temperature ranges. The obtained data on the mixing of the initial components is valuable for further studies of the processes of structure formation during photocuring of compositions, regulation of the phase structure and, as a consequence, the performance characteristics of the 3D printable materials.

Additive manufacturing of micro-architected metals via hydrogel infusion

Metal additive manufacturing (AM) enables the production of high value and high performance components1 with applications from aerospace2 to biomedical3 fields. Layer-by-layer fabrication circumvents the geometric limitations of traditional metalworking techniques, allowing topologically optimized parts to be made rapidly and efficiently4,5. Existing AM techniques rely on thermally initiated melting or sintering for part shaping, a costly and material-limited process6-8. We report an AM technique that produces metals and alloys with microscale resolution via vat photopolymerization (VP). Three-dimensional-architected hydrogels are infused with metal precursors, then calcined and reduced to convert the hydrogel scaffolds into miniaturized metal replicas. This approach represents a paradigm shift in VP; the material is selected only after the structure is fabricated. Unlike existing VP strategies, which incorporate target materials or precursors into the photoresin during printing9-11, our method does not require reoptimization of resins and curing parameters for different materials, enabling quick iteration, compositional tuning and the ability to fabricate multimaterials. We demonstrate AM of metals with critical dimensions of approximately 40 µm that are challenging to fabricate by using conventional processes. Such hydrogel-derived metals have highly twinned microstructures and unusually high hardness, providing a pathway to create advanced metallic micromaterials.

3D-printing nanocrystals with light

Nanocrystals are connected to form complex 3D structures by means of two-photon lithography.

3D-Printed Drug Capture Materials Based on Genomic DNA Coatings

The toxic side effects of chemotherapy have long limited its efficacy, prompting expensive and long-drawn efforts to develop more targeted cancer therapeutics. An alternative approach to mitigate off-target toxicity is to develop a device that can sequester chemotherapeutic agents from the veins that drain the target organ before they enter systemic circulation. This effectively localizes the chemotherapy to the target organ, minimizing any hazardous side effects. 3D printing is ideal for fabricating these devices, as the geometric control afforded allows us to precisely dictate its hemodynamic performance in vivo. However, the existing materials compatible with 3D printing do not have drug-binding capabilities. Here, we report the stable coating of genomic DNA on a 3D-printed structure for the capture of doxorubicin. Genomic DNA is an effective chemotherapeutic-agent capture material due to the intrinsic DNA-targeting mechanism of action of these drugs. Stable DNA coatings were achieved through a combination of electrostatic interactions and ultraviolet C (UVC, 254 nm) cross-linking. These UVC cross-linked DNA coatings were extremely stable-leaching on average 100 pg of genomic DNA per mm2 of 3D-printed structure over a period of 30 min. In vitro studies of these materials in phosphate buffered saline and human serum demonstrated that they were able to capture, on average, 72 and 60 ng of doxorubicin per mm2 of structure, respectively. The stability and efficacy of these genomic DNA-coated 3D-printed materials represent a significant step forward towards the translation of these devices to clinical applications for the potential improvement of chemotherapy treatment.

Balancing Self-Healing and Shape Stability in Dynamic Covalent Photoresins for Stereolithography 3D Printing

Dynamic covalent bonds impart new properties to 3D printable materials that help to establish 3D printing as an accessible and efficient manufacturing technique. Here, we studied the effect of a thermally reversible Diels-Alder cross-linker on the shape stability of photoprintable resins and their self-healing properties. Resins containing different concentrations of dynamic covalent cross-links in a polyacrylate network showed that the content of dynamic cross-links plays a key role in balancing shape stability with self-healing ability. The shape stability of the printed objects was evaluated by measuring the dimensional changes after thermal treatment. The self-healing efficiency of the 3D printed resins was characterized with a scratch test and tensile testing. A dynamic covalent cross-link concentration of 1.8 mol % was enough to provide 99% self-healing efficiency without disrupting the shape stability of the printed objects. Our work shows the potential of dynamic covalent bonds in broadening the availability of 3D printable materials that are compatible with vat photopolymerization.