Three-Dimensional Printing Hollow Polymer Template-Mediated Graphene Lattices with Tailorable Architectures and Multifunctional Properties

Nanoparticle Assembly: From Self-Organization to Controlled Micropatterning for Enhanced Functionalities

Nanoparticles form long-range micropatterns via self-assembly or directed self-assembly with superior mechanical, electrical, optical, magnetic, chemical, and other functional properties for broad applications, such as structural supports, thermal exchangers, optoelectronics, microelectronics, and robotics. The precisely defined particle assembly at the nanoscale with simultaneously scalable patterning at the microscale is indispensable for enabling functionality and improving the performance of devices. This article provides a comprehensive review of nanoparticle assembly formed primarily via the balance of forces at the nanoscale (e.g., van der Waals, colloidal, capillary, convection, and chemical forces) and nanoparticle-template interactions (e.g., physical confinement, chemical functionalization, additive layer-upon-layer). The review commences with a general overview of nanoparticle self-assembly, with the state-of-the-art literature review and motivation. It subsequently reviews the recent progress in nanoparticle assembly without the presence of surface templates. Manufacturing techniques for surface template fabrication and their influence on nanoparticle assembly efficiency and effectiveness are then explored. The primary focus is the spatial organization and orientational preference of nanoparticles on non-templated and pre-templated surfaces in a controlled manner. Moreover, the article discusses broad applications of micropatterned surfaces, encompassing various fields. Finally, the review concludes with a summary of manufacturing methods, their limitations, and future trends in nanoparticle assembly.

Diffusiophoresis-enhanced particle deposition for additive manufacturing

The ability to govern particle assembly in an evaporative-driven additive manufacturing (AM) can realize multi-scale features fundamental to creating printed electronics. However, existing techniques remain challenging and often require templates or contaminating solutes. We explore the control of particle deposition in 3D-printed colloids by diffusiophoresis, a previously unexplored mechanism in multi-scale AM. Diffusiophoresis can introduce spontaneous phoretic particle motion by establishing local solute concentration gradients. We show that diffusiophoresis can play a dominant role in complex evaporative-driven particle assembly, enabling a fundamentally new and versatile control of particle deposition in a multi-scale AM process.

Stereolithography 3D Printed Carbon Microlattices with Hierarchical Porosity for Structural and Functional Applications

Hierarchically porous carbon microlattices (HPCMLs) fabricated by using a composite photoresin and stereolithography (SLA) 3D printing is reported. Containing magnesium oxide nanoparticles (MgO NPs) as porogens and multilayer graphene nanosheets as UV-scattering inhibitors, the composite photoresin is formed to simple cubic microlattices with digitally designed porosity of 50%. After carbonization in vacuum at 1000 °C and chemical removal of MgO NPs, it is realized that carbon microlattices possessing hierarchical porosity are composed of the lattice architecture (≈100 µm), macropores (≈5 µm), mesopores (≈50 nm), and micropores (≈1 nm). The linear shrinkage after pyrolysis is as small as 33%. Compressive strength of 7.45 to 10.45 MPa and Young's modulus of 375 to 736 MPa are achieved, proving HPCMLs a robust mechanical component among reported carbon materials with a random pore structure. Having a few millimeters in thickness, the HPCMLs can serve as thick supercapacitor electrodes that demonstrate gravimetric capacitances 105 and 13.8 F g-1 in aqueous and organic electrolyte, reaching footprint areal capacitances beyond 10 and 1 F cm-2 , respectively. The results present that the composite photoresin for SLA can yield carbon microarchitectures that integrate structural and functional properties for structural energy storages .

3D Printing of Bioactive Gel-like Double Emulsion into a Biocompatible Hierarchical Macroporous Self-Lubricating Scaffold for 3D Cell Culture

The interconnected hierarchically porous structures are of key importance for potential applications as substrates for drug delivery, cell culture, and bioscaffolds, ensuring cell adhesion and sufficient diffusion of metabolites and nutrients. Here, encapsulation of a vitamin C-loaded gel-like double emulsion using a hydrophobic emulsifier and soy particles was performed to develop a bioactive bioink for 3D printing of highly porous scaffolds with enhanced cell biocompatibility. The produced double emulsions suggested a mechanical strength with the range of elastic moduli of soft tissues possessing a thixotropic feature and recoverable matrix. The outstanding flow behavior and viscoelasticity broaden the potential of gel-like double emulsion to engineer 3D scaffolds, in which 3D constructs showed a high level of porosity and excellent shape fidelity with antiwearing and self-lubricating properties. Investigation of cell viability and proliferation using fibroblasts (NIH-3T3) within vitamin C-loaded gel-like bioinks revealed that printed 3D scaffolds offered brilliant biocompatibility and cell adhesion. Compared to scaffolds without encapsulated vitamin C, 3D scaffolds containing vitamin C showed higher cell viability after 1 week of cell proliferation. This work represented a systematic investigation of hierarchical self-assembly in double emulsions and offered insights into mechanisms that control microstructure within supramolecular structures, which could be instructive for the design of advanced functional tissues.

Chemically bonded multi-nanolayer inorganic aerogel with a record-low thermal conductivity in a vacuum

Inorganic aerogels have exhibited many superior characteristics with extensive applications, but are still plagued by a nearly century-old tradeoff between their mechanical and thermal properties. When reducing thermal conductivity by ultralow density, inorganic aerogels generally suffer from large fragility due to their brittle nature or weak joint crosslinking, while enhancing the mechanical robustness by material design and structural engineering, they easily sacrifice thermal insulation and stability. Here, we report a chemically bonded multi-nanolayer design and synthesis of a graphene/amorphous boron nitride aerogel to address this typical tradeoff to further enhance mechanical and thermal properties. Attributed to the chemically bonded interface and coupled toughening effect, our aerogels display a low density of 0.8 mg cm-3 with ultrahigh flexibility (elastic compressive strain up to 99% and bending strain up to 90%), and exceptional thermostability (strength degradation <3% after sharp thermal shocks), as well as the lowest thermal conductivities in a vacuum (only 1.57 mW m-1 K-1 at room temperature and 10.39 mW m-1 K-1 at 500°C) among solid materials to date. This unique combination of mechanical and thermal properties offers an attractive material system for thermal superinsulation at extreme conditions.

3D Printed Graphene-Based Metamaterials: Guesting Multi-Functionality in One Gain

Advanced functional materials with fascinating properties and extended structural design have greatly broadened their applications. Metamaterials, exhibiting unprecedented physical properties (mechanical, electromagnetic, acoustic, etc.), are considered frontiers of physics, material science, and engineering. With the emerging 3D printing technology, the manufacturing of metamaterials becomes much more convenient. Graphene, due to its superior properties such as large surface area, superior electrical/thermal conductivity, and outstanding mechanical properties, shows promising applications to add multi-functionality into existing metamaterials for various applications. In this review, the aim is to outline the latest developments and applications of 3D printed graphene-based metamaterials. The structure design of different types of metamaterials and the fabrication strategies for 3D printed graphene-based materials are first reviewed. Then the representative explorations of 3D printed graphene-based metamaterials and multi-functionality that can be introduced with such a combination are further discussed. Subsequently, challenges and opportunities are provided, seeking to point out future directions of 3D printed graphene-based metamaterials.

Direct Conversion of Liquid Organic Precursor into 3D Laser-Induced Graphene Materials

Among the different states of matter, liquids have particular advantages in terms of easy handling and recycling, which has been manifested in various chemosynthetic reactions, but remains underexplored in graphene synthesis. This work reports the direct conversion of liquid organic precursor into versatile 3D graphene materials using rapid laser irradiation. The liquid precursor allows for easy fabrication of graphene with significant 3D architectures, including powders, patterned composite structures, and substrate-free films. Taking advantage of the high compatibility of liquid precursor with a wide range of dopants, the 3D graphene can be further engineered together with various functional components, especially the high loading (≈15 wt.%) and well-dispersed (an average diameter of less than 50 nm) high-entropy alloy nanoparticles. Furthermore, combined with the 3D printing strategy, the rapid construction of graphene with complex and accurate 3D shapes is demonstrated via a selective in situ laser transforming (SLT) strategy. With the high structural integrity unachievable by traditional 3D printing methods, the obtained objects show an electrical conductivity of 4380 S m^-1 and a compressive modulus of 31.8 MPa. The results reported in this work will open up a new way for the fabrication of functional carbon materials with customizable shapes and components.

Nanomaterial integrated 3D printing for biomedical applications

3D printing technology, otherwise known as additive manufacturing, has provided a promising tool for manufacturing customized biomaterials for tissue engineering and regenerative medicine applications. A vast variety of biomaterials including metals, ceramics, polymers, and composites are currently being used as base materials in 3D printing. In recent years, nanomaterials have been incorporated into 3D printing polymers to fabricate innovative, versatile, multifunctional hybrid materials that can be used in many different applications within the biomedical field. This review focuses on recent advances in novel hybrid biomaterials composed of nanomaterials and 3D printing technologies for biomedical applications. Various nanomaterials including metal-based nanomaterials, metal-organic frameworks, upconversion nanoparticles, and lipid-based nanoparticles used for 3D printing are presented, with a summary of the mechanisms, functional properties, advantages, disadvantages, and applications in biomedical 3D printing. To finish, this review offers a perspective and discusses the challenges facing the further development of nanomaterials in biomedical 3D printing.

Superelastic graphene aerogel-based metamaterials

Ultralight, ultrastrong, and supertough graphene aerogel metamaterials combining with multi-functionalities are promising for future military and domestic applications. However, the unsatisfactory mechanical performances and lack of the multiscale structural regulation still impede the development of graphene aerogels. Herein, we demonstrate a laser-engraving strategy toward graphene meta-aerogels (GmAs) with unusual characters. As the prerequisite, the nanofiber-reinforced networks convert the graphene walls’ deformation from the microscopic buckling to the bulk deformation during the compression process, ensuring the highly elastic, robust, and stiff nature. Accordingly, laser-engraving enables arbitrary regulation on the macro-configurations of GmAs with rich geometries and appealing characteristics such as large stretchability of 5400% reversible elongation, ultralight specific weight as small as 0.1 mg cm⁻³, and ultrawide Poisson’s ratio range from −0.95 to 1.64. Additionally, incorporating specific components into the pre-designed meta-structures could further achieve diversified functionalities.

Graphene aerogels are highly porous and have very low density; despite this they also exhibit high mechanical strength. Here the authors present a laser-engraving strategy for producing graphene meta-aerogels with different configurations and properties.

Efficient Preconstruction of Three-Dimensional Graphene Networks for Thermally Conductive Polymer Composites

Electronic devices generate heat during operation and require efficient thermal management to extend the lifetime and prevent performance degradation. Featured by its exceptional thermal conductivity, graphene is an ideal functional filler for fabricating thermally conductive polymer composites to provide efficient thermal management. Extensive studies have been focusing on constructing graphene networks in polymer composites to achieve high thermal conductivities. Compared with conventional composite fabrications by directly mixing graphene with polymers, preconstruction of three-dimensional graphene networks followed by backfilling polymers represents a promising way to produce composites with higher performances, enabling high manufacturing flexibility and controllability. In this review, we first summarize the factors that affect thermal conductivity of graphene composites and strategies for fabricating highly thermally conductive graphene/polymer composites. Subsequently, we give the reasoning behind using preconstructed three-dimensional graphene networks for fabricating thermally conductive polymer composites and highlight their potential applications. Finally, our insight into the existing bottlenecks and opportunities is provided for developing preconstructed porous architectures of graphene and their thermally conductive composites.

General Suspended Printing Strategy toward Programmatically Spatial Kevlar Aerogels

Aerogels represent a kind of nanoporous solid with immense importance for a plethora of diverse applications. However, on-demand conformal shaping capacity remains extremely challenging due to the strength unfavorable during aerogel processing. Herein, a universal microgel-directed suspended printing (MSP) strategy is developed for fabricating various mesoporous aerogels with spatially stereoscopic structures on-demand. As a proof-of-concept demonstration, through the rational design of the used microgel matrix and favorable printing of the Kevlar nanofiber inks, the Kevlar aerogels with arbitrary spatial structure have been fabricated, demonstrating excellent printability and programmability under a high-speed printing mode (up to 167 mm s^-1). Furthermore, the custom-tailored Kevlar aerogel insulator possessing superior thermal insulation attribute has ensured normal discharge capacity of the drone even under a harsh environment (-30 °C). Finally, various types of spatial 3D aerogel architectures, including organic (cellulose, alginate, chitosan), inorganic (graphene, MXene, silica), and inorganic-organic (graphene/cellulose, MXene/alginate, silica/chitosan) hybrid aerogels, have been successfully fabricated, suggesting the universality of the MSP strategy. The strategy reported here proposes an alternative for the development of various customized aerogels and stimulates the inspiration to truly arbitrary architectures for wider applications.

Recent Advances on 2D Materials towards 3D Printing

In recent years, 2D materials have been implemented in several applications due to their unique and unprecedented properties. Several examples can be named, from the very first, graphene, to transition-metal dichalcogenides (TMDs, e.g., MoS2), two-dimensional inorganic compounds (MXenes), hexagonal boron nitride (h-BN), or black phosphorus (BP). On the other hand, the accessible and low-cost 3D printers and design software converted the 3D printing methods into affordable fabrication tools worldwide. The implementation of this technique for the preparation of new composites based on 2D materials provides an excellent platform for next-generation technologies. This review focuses on the recent advances of 3D printing of the 2D materials family and its applications; the newly created printed materials demonstrated significant advances in sensors, biomedical, and electrical applications.

Extrusion-Based 3D Printing for Highly Porous Alginate Materials Production

Three-dimensional (3D) printing is a promising technology for solving a wide range of problems: regenerative medicine, tissue engineering, chemistry, etc. One of the potential applications of additive technologies is the production of highly porous structures with complex geometries, while printing is carried out using gel-like materials. However, the implementation of precise gel printing is a difficult task due to the high requirements for “ink”. In this paper, we propose the use of gel-like materials based on sodium alginate as “ink” for the implementation of the developed technology of extrusion-based 3D printing. Rheological studies were carried out for the developed alginate ink compositions. The optimal rheological properties are gel-like materials based on 2 wt% sodium alginate and 0.2 wt% calcium chloride. The 3D-printed structures with complex geometry were successfully dried using supercritical drying. The resulting aerogels have a high specific surface area (from 350 to 422 m²/g) and a high pore volume (from 3 to 3.78 cm³/g).

Three-Dimensional Graphene-Based Macrostructures for Electrocatalysis

Electrochemical energy storage and conversion is an effective strategy to relieve the increasing energy and environment crisis. The sluggish reaction kinetics in the related devices is one of the major obstacles for them to realize practical applications. More efforts should be devoted to searching for high-efficiency electrocatalysts and enhancing the electrocatalytic performance. 3D graphene macrostructures (3D GMs) are one kind of porous crystalline materials with 3D structures at both micro- and macro-scale. The unique structure can achieve large accessible surface area, expose many active sites, promote fast mass/electron transport, and provide wide room for further functional modification. All these features make them promising candidates for electrocatalysis. In this review, the authors focus on the latest progress of 3D GMs for electrocatalysis. First, the preparation methods of 3D GMs are introduced followed by the strategies for functional modifications. Then, their electrocatalytic performances are discussed in detail including monofunctional and bifunctional electrocatalysis. The electrocatalytic processes involve oxygen reduction reaction, oxygen evolution reaction, hydrogen evolution reaction, and carbon dioxide reduction reaction. Finally, the challenges and perspectives are presented to offer a guideline for the exploration of excellent 3D GM-based electrocatalysts.

3D Printing of Lightweight Polyimide Honeycombs with the High Specific Strength and Temperature Resistance

Lightweight structures are often used for applications requiring higher strength-to-weight ratios and lower densities, such as in aircraft, vehicles, and various engine components. Three-dimensional (3D) printing technology has been widely used for lightweight polymer structures because of the superior flexibility, personalized design, and ease of operation offered by it. However, synthesis of lightweight polymeric structures that possess both high specific strength and glass transfer temperature (T_g) remains an elusive goal, because 3D printed polymers with these properties are still very few in the market. For example, 3,3',4,4'-biphenyl tetracarboxylic dianhydride (BPDA) and p-phenylenediamine (PDA)-type (UPILEX-S type) polyimides show exceptional thermal stability (T_g up to ≈400 °C) and mechanical properties (tensile strength exceeding 500 MPa) and are the first choice if extremely high temperatures of 400 °C or even higher (depending on the duration) are required, which hampers their processing using existing 3D printing techniques. However, their processing using existing 3D printing techniques is hampered due to their thermal resistance. Herein, a 3D printing approach was demonstrated for generating complex lightweight BPDA-PDA polyimide geometries with unprecedented specific strength and thermal resistance. The simple aqueous polymerization reaction of BPDA with water-soluble PDA and triethylamine (TEA) afforded the poly(amic acid) ammonium salt (PAAS) hydrogels. These PAAS solutions showed clear shear thinning and thermo-reversibility, along with high G' gel-state moduli, which ensured self-supporting features and shape fidelity in the gel state. Postprinting thermal treatment transformed the PAAS precursor to BPDA-PDA polyimide (UPILEX-S type). The resulting layer-by-layer deposition onto lightweight polyimide honeycombs in the form of triangular, square, and hexagonal structures showed tailorable mechanical strength, exceptional compressive strength-to-weight ratio (highest up to 0.127 MPa (kg m^-3)^-1), and remarkable thermoresistance (T_g approximately 380 °C). These high-performance 3D printed polyimide honeycombs and unique synthetic techniques with general structures are potentially useful in fields ranging from automotive to aerospace technologies.

Printed aerogels: chemistry, processing, and applications

As an extraordinarily lightweight and porous functional nanomaterial family, aerogels have attracted considerable interest in academia and industry in recent decades. Despite the application scopes, the modest mechanical durability of aerogels makes their processing and operation challenging, in particular, for situations demanding intricate physical structures. "Bottom-up" additive manufacturing technology has the potential to address this drawback. Indeed, since the first report of 3D printed aerogels in 2015, a new interdisciplinary research area combining aerogel and printing technology has emerged to push the boundaries of structure and performance, further broadening their application scope. This review summarizes the state-of-the-art of printed aerogels and presents a comprehensive view of their developments in the past 5 years, and highlights the key near- and mid-term challenges.

3D Graphene Materials: From Understanding to Design and Synthesis Control

Carbon materials, with their diverse allotropes, have played significant roles in our daily life and the development of material science. Following 0D C₆₀ and 1D carbon nanotube, 2D graphene materials, with their distinctively fascinating properties, have been receiving tremendous attention since 2004. To fulfill the efficient utilization of 2D graphene sheets in applications such as energy storage and conversion, electrochemical catalysis, and environmental remediation, 3D structures constructed by graphene sheets have been attempted over the past decade, giving birth to a new generation of graphene materials called 3D graphene materials. This review starts with the definition, classifications, brief history, and basic synthesis chemistries of 3D graphene materials. Then a critical discussion on the design considerations of 3D graphene materials for diverse applications is provided. Subsequently, after emphasizing the importance of normalized property characterization for the 3D structures, approaches for 3D graphene material synthesis from three major types of carbon sources (GO, hydrocarbons and inorganic carbon compounds) based on GO chemistry, hydrocarbon chemistry, and new alkali-metal chemistry, respectively, are comprehensively reviewed with a focus on their synthesis mechanisms, controllable aspects, and scalability. At last, current challenges and future perspectives for the development of 3D graphene materials are addressed.

Recent progress on hollow array architectures and their applications in electrochemical energy storage

The structural design of electrode materials is one of the most important factors that determines the electrochemical performance of energy storage devices. In recent years, hollow micro-/nanoarray structures have been widely explored for energy applications due to their unique structural advantages. Their complex hollow interior and shell arrays enable fast ion diffusion/transport, provide abundant active sites and accommodate volume changes. Moreover, the direct contact of hollow arrays with substrates enhances the mechanical stability during long-term cycling. To date, huge progress has been achieved in the rational design of various hollow array architectures. However, a review on this topic has been rarely reported. Herein, the multifunctional merits and typical synthetic strategies for hollow array structures are analyzed in detail. Furthermore, their applications in electrochemical energy storage (such as supercapacitors and batteries) are summarized. The development and challenges of hollow arrays in terms of substrates, technique improvement and material innovation are discussed. Finally, their applications for energy storage and conversion are prospected.

3D Printed Mechanically Robust Graphene/CNT Electrodes for Highly Efficient Overall Water Splitting

3D printing of graphene electrodes with high mechanical strength has been a growing interest in the development of advanced energy, environment, and electronic systems, yet is extremely challenging. Herein, a 3D printed bioinspired electrode of graphene reinforced with 1D carbon nanotubes (CNTs) (3DP GC) with both high flexural strength and hierarchical porous structure is reported via a 3D printing strategy. Mechanics modeling reveals the critical role of the 1D CNTs in the enhanced flexural strength by increasing the friction and adhesion between the 2D graphene nanosheets. The 3DP GC electrodes hold distinct advantages: i) an intrinsically high flexural strength that enables their large-scale applications; and ii) a hierarchical porous structure that offers large surface area and interconnected channels, endowing fast mass and/or charge and ions transport rate, which is thus beneficial for acting as an ideal catalyst carrier. The 3DP GC electrode integrated with a NiFeP nanosheets array exhibits a voltage of 1.58 V at 30 mA cm^-2 as bifunctional electrode for water splitting, which is much better than most of the reported Ni-, Co-, and Fe-based bifunctional electrocatalysts. Importantly, this study paves the way for the practical applications of 3D printed graphene electrodes in many energy conversion/storage, environmental, and electronic systems where high flexural strength is preferred.

Freeze Casting: From Low-Dimensional Building Blocks to Aligned Porous Structures-A Review of Novel Materials, Methods, and Applications

Freeze casting, also known as ice templating, is a particularly versatile technique that has been applied extensively for the fabrication of well-controlled biomimetic porous materials based on ceramics, metals, polymers, biomacromolecules, and carbon nanomaterials, endowing them with novel properties and broadening their applicability. The principles of different directional freeze-casting processes are described and the relationships between processing and structure are examined. Recent progress in freeze-casting assisted assembly of low dimensional building blocks, including graphene and carbon nanotubes, into tailored micro- and macrostructures is then summarized. Emerging trends relating to novel materials as building blocks and novel freeze-cast geometries-beads, fibers, films, complex macrostructures, and nacre-mimetic composites-are presented. Thereafter, the means by which aligned porous structures and nacre mimetic materials obtainable through recently developed freeze-casting techniques and low-dimensional building blocks can facilitate material functionality across multiple fields of application, including energy storage and conversion, environmental remediation, thermal management, and smart materials, are discussed.

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.

3D-Printed Ultra-Robust Surface-Doped Porous Silicone Sensors for Wearable Biomonitoring

Three-dimensional flexible porous conductors have significantly advanced wearable sensors and stretchable devices because of their specific high surface area. Dip coating of porous polymers with graphene is a facile, low cost, and scalable approach to integrate conductive layers with the flexible polymer substrate platforms; however, the products often suffer from nanoparticle delamination and overtime decay. Here, a fabrication scheme based on accessible methods and safe materials is introduced to surface-dope porous silicone sensors with graphene nanoplatelets. The sensors are internally shaped with ordered, interconnected, and tortuous internal geometries (i.e., triply periodic minimal surfaces) using fused deposition modeling (FDM) 3D-printed sacrificial molds. The molds were dip coated to transfer-embed graphene onto the silicone rubber (SR) surface. The presented procedure exhibited a stable coating on the porous silicone samples with long-term electrical resistance durability over ∼12 months period and high resistance against harsh conditions (exposure to organic solvents). Besides, the sensors retained conductivity upon severe compressive deformations (over 75% compressive strain) with high strain-recoverability and behaved robustly in response to cyclic deformations (over 400 cycles), temperature, and humidity. The sensors exhibited a gauge factor as high as 10 within the compressive strain range of 2-10%. Given the tunable sensitivity, the engineered biocompatible and flexible devices captured movements as rigorous as walking and running to the small deformations resulted by human pulse.

3D Printing of Ultralight Biomimetic Hierarchical Graphene Materials with Exceptional Stiffness and Resilience

Biological materials with hierarchical architectures (e.g., a macroscopic hollow structure and a microscopic cellular structure) offer unique inspiration for designing and manufacturing advanced biomimetic materials with outstanding mechanical performance and low density. Most conventional biomimetic materials only benefit from bioinspired architecture at a single length scale (e.g., microscopic material structure), which largely limits the mechanical performance of the resulting materials. There exists great potential to maxime the mechanical performance of biomimetic materials by leveraging a bioinspired hierarchical structure. An ink-based three-dimensional (3D) printing strategy to manufacture an ultralight biomimetic hierarchical graphene material (BHGMs) with exceptionally high stiffness and resilience is demonstrated. By simultaneously engineering 3D-printed macroscopic hollow structures and constructing an ice-crystal-induced cellular microstructure, BHGMs can achieve ultrahigh elasticity and stability at compressive strains up to 95%. Multiscale finite element analyses indicate that the hierarchical structures of BHGMs effectively reduce the macroscopic strain and transform the microscopic compressive deformation into the rotation and bending of the interconnected graphene flakes. This 3D printing strategy demonstrates the great potential that exists for the assembly of other functional materials into hierarchical cellular structures for various applications where high stiffness and resilience at low density are simultaneously required.

Structurally Controlled Cellular Architectures for High-Performance Ultra-Lightweight Materials

The design and synthesis of cellular structured materials are of both scientific and technological importance since they can impart remarkably improved material properties such as low density, high mechanical strength, and adjustable surface functionality compared to their bulk counterparts. Although reducing the density of porous structures would generally result in reductions in mechanical properties, this challenge can be addressed by introducing a structural hierarchy and using mechanically reinforced constituent materials. Thus, precise control over several design factors in structuring, including the type of constituent, symmetry of architectures, and dimension of the unit cells, is extremely important for maximizing the targeted performance. The feasibility of lightweight materials for advanced applications is broadly explored due to recent advances in synthetic approaches for different types of cellular architectures. Here, an overview of the development of lightweight cellular materials according to the structural interconnectivity and randomness of the internal pores is provided. Starting from a fundamental study on how material density is associated with mechanical performance, the resulting structural and mechanical properties of cellular materials are investigated for potential applications such as energy/mass absorption and electrical and thermal management. Finally, current challenges and perspectives on high-performance ultra-lightweight materials potentially implementable by well-controlled cellular architectures are discussed.

Nanomaterials in Advanced, High-Performance Aerogel Composites: A Review

Aerogels are one of the most interesting materials of the 21st century owing to their high porosity, low density, and large available surface area. Historically, aerogels have been used for highly efficient insulation and niche applications, such as interstellar particle capture. Recently, aerogels have made their way into the composite universe. By coupling nanomaterial with a variety of matrix materials, lightweight, high-performance composite aerogels have been developed for applications ranging from lithium-ion batteries to tissue engineering materials. In this paper, the current status of aerogel composites based on nanomaterials is reviewed and their application in environmental remediation, energy storage, controlled drug delivery, tissue engineering, and biosensing are discussed.

Metallization of 3D Printed Polymers and Their Application as a Fully Functional Water-Splitting System

In this work, the plating of high-quality amorphous nickel-phosphorous coating with low resistivity of 0.45 µΩ m (298 K) on complex 3D printed polymeric structures with high uniformity is reported. Such a polymer metallization results in an effective conductivity of 4.7 × 104 S m-1. This process also allows flexible structures to maintain their flexibility along with the conductivity. Octet-truss structures with nickel-iron-(oxo) hydroxide nanosheets electrodeposited onto further displays excellent water-splitting performance as catalytic electrodes, i.e., in KOH (1 m, aq), a low oxygen evolution reaction (OER) overpotential of 197 mV at 10 mA cm-2 and Tafel slope of 51 mV dec-1. Using this light-weight electrode with high specific area, strength, and corrosion resistance properties, a fully functional water-splitting system is designed and fabricated through the concentric integration of 3D printed components. A dense polymeric mesh implemented is also demonstrated as an effective separator of hydrogen and oxygen bubbles in this system.