Printing Carbon Nanotube-Embedded Silicone Elastomers via Direct Writing

Carbon-Based Piezoresistive Polymer Nanocomposites by Extrusion Additive Manufacturing: Process, Material Design, and Current Progress

Advancement in additive manufacturing (AM) allows the production of nanocomposites with complex and custom geometries not typically allowable with conventional manufacturing techniques. The benefits of AM have led to recent interest in producing multifunctional materials capable of being printed with current AM technologies. In this article, piezoresistive composites realized by AM and the matrices and fillers utilized to make such devices are introduced and discussed. Carbon-based nanoparticles (Carbon Nanotubes, Graphene/Graphite, and Carbon Black) are often the filler choice of most researchers and are heavily discussed throughout this review in combination with extrusion AM methods. Piezoresistive applications such as physiological and wearable sensors, structural health monitoring, and soft robotics are presented with an emphasis on material and AM selection to meet the demands of such applications.

Selective Laser Sintering of Polydimethylsiloxane Composites

Conductive silicone elastomer carbon nanotubes (CNTs) composites possess potential applications in a variety of fields, including electronic skin, wearable electronics, and human motion detection. Based on a novel self-made covalent adaptable network (CANs) of polydimethylsiloxane (PDMS) containg dynamic steric-hindrance pyrazole urea bond (PDMS-CANs), CNTs wrapped PDMS-CANs (CNTs@PDMS-CANs) powders were prepared by a liquid phase adsorption and deposition, and were successfully used for selective laser sintering (SLS) three-dimensional printing. SLS-printed PDMS-CANs/CNTs nanocomposites possess high electrical conductivity and low percolation threshold as SLS is one kind of quasi-static processing, which leads to the formation of conductive segregated CNTs network by using the PDMS powders with special CNTs wrapped structure. The introduction of dynamic pyrazole urea bond endows the materials self-healing capability under electrothermal and photothermal stimulus. In addition, due to the resistance difference of the damaged and intact areas, crack diagnosing can be realized by infrared thermograph under electricity. In an application demonstration in strain sensor, the composite exhibits a regular cyclic electrical resistance change at cyclic compression and bending, indicating a relative high reliability.

Direct Ink Writing of Carbon-Doped Polymeric Composite Ink: A Review on Its Requirements and Applications

Direct Ink Writing (DIW) opens new possibilities in three-dimensional (3D) printing of carbon-based polymeric ink. This is due to its ability in design flexibility, structural complexity, and environmental sustainability. This area requires exhaustive study because of its wide application in different manufacturing sectors. The present article is related to the variant emerging 3D printing techniques and DIW of carbonaceous materials. Carbon-based materials, extensively used for various applications in 3D printing, possess impressive chemical stability, strength, and flexible nanostructure. Fine printable inks consist predominantly of uniform solutions of carbon materials, such as graphene, graphene oxide (GO), carbon fibers (CFs), carbon nanotubes (CNTs), and solvents. It also contains compatible polymers and suitable additives. This review article elaborately discusses the fundamental requirements of DIW in structuring carbon-doped polymeric inks viz. ink formulation, required ink rheology, extrusion parameters, print fidelity prediction, layer bonding examination, substrate selection, and curing method to achieve fine functional composites. A detailed description of its application in the fields of electronics, medical, and mechanical segments have also been focused in this study.

Recent Advances in Multi-Material 3D Printing of Functional Ceramic Devices

In recent years, functional ceramic devices have become smaller, thinner, more refined, and highly integrated, which makes it difficult to realize their rapid prototyping and low-cost manufacturing using traditional processing. As an emerging technology, multi-material 3D printing offers increased complexity and greater freedom in the design of functional ceramic devices because of its unique ability to directly construct arbitrary 3D parts that incorporate multiple material constituents without an intricate process or expensive tools. Here, the latest advances in multi-material 3D printing methods are reviewed, providing a comprehensive study on 3D-printable functional ceramic materials and processes for various functional ceramic devices, including capacitors, multilayer substrates, and microstrip antennas. Furthermore, the key challenges and prospects of multi-material 3D-printed functional ceramic devices are identified, and future directions are discussed.

3D Printing of Short-Carbon-Fiber-Reinforced Thermoset Polymer Composites via Frontal Polymerization

3D printing of fiber-reinforced thermoset composites is desirable for rapid fabrication of 3D composite objects with minimal tooling. One of the main issues in 3D printing of thermoset composites is the low cure rates of matrix resins, which prevents rapid curing and rigidization of composite materials during the printing process and capturing the desired print geometry. Here, we demonstrate a new technique for in situ printing and curing of carbon-fiber-reinforced thermoset composites without any postcuring or postprocessing steps. Upon extrusion and deposition of the composite ink from a printing nozzle, the ink is cured via frontal polymerization, leading to rapid printing of high-quality composites. Tailoring the processing conditions allows for freeform or rapid, supported printing of 3D composite objects with zero void content and highly oriented carbon fiber reinforcements.

Chitin nanocrystals assisted 3D printing of polycitrate thermoset bioelastomers

Citrate-based thermoset bioelastomer has numerous tissue engineering applications. However, its insoluble and unmeltable features restricted processing techniques for fabricating complex scaffolds. Herein, direct ink writing (DIW) was explored for 3D printing of poly(1, 8-octanediol-co-Pluronic F127 citrate) (POFC) bioelastomer scaffolds considering that POFC prepolymer (pre-POFC) was waterborne and could form a stable emulsion. The pre-POFC emulsion couldn't be printed, however, chitin nanocrystal (ChiNC) could be as a rheological modifier to tune the flow behavior of pre-POFC emulsion, and thus DIW printing of POFC scaffolds was successfully realized; moreover, ChiNC was also as a supporting agent to prevent collapse of filaments during thermocuring, and simultaneously as a biobased nanofiller to reinforce scaffolds. The rheological analyses showed the pre-POFC/ChiNC inks fulfilled the requirements for DIW printing. The printed scaffolds exhibited low swelling, and good performances in strength and resilence. Furthermore, the entire process was easily performed and eco-friendly.

3D-Printable Carbon Nanotubes-Based Composite for Flexible Piezoresistive Sensors

The intersection between nanoscience and additive manufacturing technology has resulted in a new field of printable and flexible electronics. This interesting area of research tackles the challenges in the development of novel materials and fabrication techniques towards a wider range and improved design of flexible electronic devices. This work presents the fabrication of a cost-effective and facile flexible piezoresistive pressure sensor using a 3D-printable carbon nanotube-based nanocomposite. The carbon nanotubes used for the development of the material are multi-walled carbon nanotubes (MWCNT) dispersed in polydimethylsiloxane (PDMS) prepolymer. The sensor was fabricated using the direct ink writing (DIW) technique (also referred to as robocasting). The MWCNT-PDMS composite was directly printed onto the polydimethylsiloxane substrate. The sensor response was then examined based on the resistance change to the applied load. The sensor exhibited high sensitivity (6.3 Ω/kPa) over a wide range of applied pressure (up to 1132 kPa); the highest observed measurement range for MWCNT-PDMS composite in previous work was 40 kPa. The formulated MWCNT-PDMS composite was also printed into high-resolution 3-dimensional shapes which maintained their form even after heat treatment process. The possibility to use 3D printing in the fabrication of flexible sensors allows design freedom and flexibility, and structural complexity with wide applications in wearable or implantable electronics for sport, automotive and biomedical fields.

Advancements in Microfabricated Gas Sensors and Microanalytical Tools for the Sensitive and Selective Detection of Odors

In recent years, advancements in micromachining techniques and nanomaterials have enabled the fabrication of highly sensitive devices for the detection of odorous species. Recent efforts done in the miniaturization of gas sensors have contributed to obtain increasingly compact and portable devices. Besides, the implementation of new nanomaterials in the active layer of these devices is helping to optimize their performance and increase their sensitivity close to humans' olfactory system. Nonetheless, a common concern of general-purpose gas sensors is their lack of selectivity towards multiple analytes. In recent years, advancements in microfabrication techniques and microfluidics have contributed to create new microanalytical tools, which represent a very good alternative to conventional analytical devices and sensor-array systems for the selective detection of odors. Hence, this paper presents a general overview of the recent advancements in microfabricated gas sensors and microanalytical devices for the sensitive and selective detection of volatile organic compounds (VOCs). The working principle of these devices, design requirements, implementation techniques, and the key parameters to optimize their performance are evaluated in this paper. The authors of this work intend to show the potential of combining both solutions in the creation of highly compact, low-cost, and easy-to-deploy platforms for odor monitoring.

Self-Repairing, Large Linear Working Range Shape Memory Carbon Nanotubes/Ethylene Vinyl Acetate Fiber Strain Sensor for Human Movement Monitoring

Flexible strain sensors have shown great application value in wearable devices. In the past decades, researchers have spent numerous efforts on developing high-stretchability, excellent dynamic durability, and large linear working range flexible strain sensors and shaped a series of important research results. However, the viscoelasticity of the elastic polymer is always a big challenge to develop a flexible sensor. Here, to overcome this challenge, we developed a novel self-repairing carbon nanotubes/ethylene vinyl acetate (CNTs/EVA) fiber strain sensor prepared by embedding the CNTs on the surface of the swollen shape memory EVA fiber via the ultrasonic method. The CNTs/EVA fiber strain sensors responded with significant results, with high stretchability (190% strain), large linear working range (up to 88% strain), excellent dynamic durability (5000 cycles), and fast response speed (312 ms). In addition, the permanently damaged conductive network of the strain sensors, caused by the viscoelasticity of elastic polymer, can restore above the transforming temperature of the shape memory CNTs/EVA fiber. Moreover, the performance of the restored strain sensors was almost as same as that of the original strain sensors. Furthermore, human health monitoring tests show that the CNTs/EVA fiber has a broad application prospect for human health monitoring in wearable electronic devices.

Superstretchable and Processable Silicone Elastomers by Digital Light Processing 3D Printing

A series of photosensitive resins suitable for the production of silicone elastomers through digital light processing 3D printing are reported. Based on thiol-ene click reaction between a branched mercaptan-functionalized polysiloxane and different-molecular-weight vinyl-terminated poly(dimethylsiloxane), silicone elastomers with tunable hardness and mechanical properties are obtained. Printed elastomeric objects show high printing resolution and excellent mechanical properties. The break elongation of the silicone elastomers can get up to 1400%, which is much higher than the reported UV-cured elastomers and is even higher than the most stretchable thermocuring silicone elastomers. The superstretchable silicone elastomers are then applied to fabricate stretchable electronics with carbon nanotubes-doped hydrogel. The printable and processable silicone elastomers have great potential applications in various fields, including soft robotics, flexible actuators, and medical implants.