Direct printing of functional 3D objects using polymerization-induced phase separation

3D printed PEDOT:PSS-based conducting and patternable eutectogel electrodes for machine learning on textiles

The proliferation of medical wearables necessitates the development of novel electrodes for cutaneous electrophysiology. In this work, poly(3,4-ethylenedioxythiophene) polystyrene sulfonate (PEDOT:PSS) is combined with a deep eutectic solvent (DES) and polyethylene glycol diacrylate (PEGDA) to develop printable and biocompatible electrodes for long-term cutaneous electrophysiology recordings. The impact of printing parameters on the conducting properties, morphological characteristics, mechanical stability and biocompatibility of the material were investigated. The optimised eutectogel formulations were fabricated in four different patterns -flat, pyramidal, striped and wavy- to explore the influence of electrode geometry on skin conformability and mechanical contact. These electrodes were employed for impedance and forearm EMG measurements. Furthermore, arrays of twenty electrodes were embedded into a textile and used to generate body surface potential maps (BSPMs) of the forearm, where different finger movements were recorded and analysed. Finally, BSPMs for three different letters (B, I, O) in sign-language were recorded and used to train a logistic regressor classifier able to reliably identify each letter. This novel cutaneous electrode fabrication approach offers new opportunities for long-term electrophysiological recordings, online sign-language translation and brain-machine interfaces.

Toward Multiscale, Multimaterial 3D Printing

Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.

Kinetically controlled metal-elastomer nanophases for environmentally resilient stretchable electronics

Nanophase mixtures, leveraging the complementary strengths of each component, are vital for composites to overcome limitations posed by single elemental materials. Among these, metal-elastomer nanophases are particularly important, holding various practical applications for stretchable electronics. However, the methodology and understanding of nanophase mixing metals and elastomers are limited due to difficulties in blending caused by thermodynamic incompatibility. Here, we present a controlled method using kinetics to mix metal atoms with elastomeric chains on the nanoscale. We find that the chain migration flux and metal deposition rate are key factors, allowing the formation of reticular nanophases when kinetically in-phase. Moreover, we observe spontaneous structural evolution, resulting in gyrified structures akin to the human brain. The hybridized gyrified reticular nanophases exhibit strain-invariant metallic electrical conductivity up to 156% areal strain, unparalleled durability in organic solvents and aqueous environments with pH 2-13, and high mechanical robustness, a prerequisite for environmentally resilient devices.

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.

Polymerization Induced Microphase Separation of ABC Triblock Copolymers for 3D Printing Nanostructured Materials

Polymerization-induced microphase separation (PIMS) is a versatile technique for producing nanostructured materials. In previous PIMS studies, the predominant approach involved employing homopolymers as macromolecular chain transfer agents (macroCTAs) to mediate the formation of nanostructured materials. In this article, the use of AB diblock copolymers as macroCTAs to design PIMS systems for 3D printing of nanostructured materials is investigated. Specifically, the influence of diblock copolymer composition and block sequence on the resulting nanostructures, and their subsequent impact on bulk properties is systematically investigated. Through careful manipulation of the A/B block ratios, the morphology and size of the nanodomains are successfully controlled. Remarkably, the sequence of A and B blocks significantly affects the microphase separation process, resulting in distinct morphologies. The effect can be attributed to changes in the interaction parameters (χAB , χBC , χAC ) between the different block segments. Furthermore, the block sequence and composition exert profound influence on the thermomechanical, tensile, and swelling properties of 3D printed nanostructured materials. By leveraging this knowledge, it becomes possible to design advanced 3D printable materials with tailored properties, opening new avenues for material engineering.

Supramolecular chemistry enables vat photopolymerization 3D printing of novel water-soluble tablets

Vat photopolymerization has garnered interest from pharmaceutical researchers for the fabrication of personalised medicines, especially for drugs that require high precision dosing or are heat labile. However, the 3D printed structures created thus far have been insoluble, limiting printable dosage forms to sustained-release systems or drug-eluting medical devices which do not require dissolution of the printed matrix. Resins that produce water-soluble structures will enable more versatile drug release profiles and expand potential applications. To achieve this, instead of employing cross-linking chemistry to fabricate matrices, supramolecular chemistry may be used to impart dynamic interaction between polymer chains. In this study, water-soluble drug-loaded printlets (3D printed tablets) are fabricated via digital light processing (DLP) 3DP for the first time. Six formulations with varying ratios of an electrolyte acrylate monomer, [2-(acryloyloxy)ethyl]trimethylammonium chloride (TMAEA), and a co-monomer, 1-vinyl-2-pyrrolidone (NVP), were prepared to produce paracetamol-loaded printlets. 1H NMR spectroscopy analysis confirmed the integration of TMAEA and NVP in the polymer, and residual TMAEA monomers were found to be present only in trace amounts (0.71 - 1.37 %w/w). The apparent molecular mass of the photopolymerised polymer was found to exceed 300,000 Da with hydrodynamic radii of 15 - 20 nm, estimated based on 1H DOSY NMR measurements The loaded paracetamol was completely released from the printlets between 45 minutes to 5 hours. In vivo single-dose acute toxicity studies in rats suggest that the printlets did not cause any tissue damage. The findings reported in this study represent a significant step towards the adoption of vat photopolymerization-based 3DP to produce personalised medicines.

Wearable Electronics Based on Stretchable Organic Semiconductors

Wearable electronics are attracting increasing interest due to the emerging Internet of Things (IoT). Compared to their inorganic counterparts, stretchable organic semiconductors (SOSs) are promising candidates for wearable electronics due to their excellent properties, including light weight, stretchability, dissolubility, compatibility with flexible substrates, easy tuning of electrical properties, low cost, and low temperature solution processability for large-area printing. Considerable efforts have been dedicated to the fabrication of SOS-based wearable electronics and their potential applications in various areas, including chemical sensors, organic light emitting diodes (OLEDs), organic photodiodes (OPDs), and organic photovoltaics (OPVs), have been demonstrated. In this review, some recent advances of SOS-based wearable electronics based on the classification by device functionality and potential applications are presented. In addition, a conclusion and potential challenges for further development of SOS-based wearable electronics are also discussed.

Multi-Material Additively Manufactured Magnetoelectric Architectures with a Structure-Dependent Mechanical-to-Electrical Conversion Capability

Multi-material additive manufacturing has become a promising trend in fabricating advanced functional architectures due to its controllable design of diverse material species and novel structures. It remains challenging to endow the multi-material components with a mechanical-to-electrical conversion capability. This study reports on multi-material selectively laser sintered magnetoelectric architectures that can convert mechanical energy to electricity in a structure-dependent manner. The principal aim is to establish a relationship between the electrical output and the printed structures by fabricating a series of porous architectures with diverse structural parameters. The findings show that the output voltage increases with the decrease of the elastic modulus and the increase of the magnetic height, which has been analyzed by numerical simulation. Owing to the mechanical-to-electrical conversion capability, a pair of multi-material printed sneakers with the functionalities of power generation and gait analysis has been prepared. The voltage output reaches as high as ≈2 V, which can lighten a light-emitting diode lamp when a user is running. The described solution in this work has offered an exploration framework for the design, fabrication, and application prospects of multi-material additively manufactured architectures.

Designing Nanostructured 3D Printed Materials by Controlling Macromolecular Architecture

Nanostructured polymeric materials play important roles in many advanced applications, however, controlling the morphologies of polymeric thermosets remains a challenge. This work uses multi-arm macroCTAs to mediate polymerization-induced microphase separation (PIMS) and prepare nanostructured materials via photoinduced 3D printing. The characteristic length scale of microphase-separated domains is determined by the macroCTA arm length, while nanoscale morphologies are controlled by the macroCTA architecture. Specifically, using 2- and 4- arm macroCTAs provides materials with different morphologies compared to analogous monofunctional linear macroCTAs at similar compositions. The mechanical properties of these nanostructured thermosets can also be tuned while maintaining the desired morphologies. Using multi-arm macroCTAs can thus broaden the scope of accessible nanostructures for extended applications, including the fabrication of actuators and potential drug delivery devices.

Nano- to macro-scale control of 3D printed materials via polymerization induced microphase separation

Although 3D printing allows the macroscopic structure of objects to be easily controlled, controlling the nanostructure of 3D printed materials has rarely been reported. Herein, we report an efficient and versatile process for fabricating 3D printed materials with controlled nanoscale structural features. This approach uses resins containing macromolecular chain transfer agents (macroCTAs) which microphase separate during the photoinduced 3D printing process to form nanostructured materials. By varying the chain length of the macroCTA, we demonstrate a high level of control over the microphase separation behavior, resulting in materials with controllable nanoscale sizes and morphologies. Importantly, the bulk mechanical properties of 3D printed objects are correlated with their morphologies; transitioning from discrete globular to interpenetrating domains results in a marked improvement in mechanical performance, which is ascribed to the increased interfacial interaction between soft and hard domains. Overall, the findings of this work enable the simplified production of materials with tightly controllable nanostructures for broad potential applications.

Microencapsulation-based cell therapies

Mapping a new therapeutic route can be fraught with challenges, but recent developments in the preparation and properties of small particles combined with significant improvements to tried and tested techniques offer refined cell targeting with tremendous translational potential. Regenerating new cells through the use of compounds that regulate epigenetic pathways represents an attractive approach that is gaining increased attention for the treatment of several diseases including Type 1 Diabetes and cardiomyopathy. However, cells that have been regenerated using epigenetic agents will still encounter immunological barriers as well as limitations associated with their longevity and potency during transplantation. Strategies aimed at protecting these epigenetically regenerated cells from the host immune response include microencapsulation. Microencapsulation can provide new solutions for the treatment of many diseases. In particular, it offers an advantageous method of administering therapeutic materials and molecules that cannot be substituted by pharmacological substances. Promising clinical findings have shown the potential beneficial use of microencapsulation for islet transplantation as well as for cardiac, hepatic, and neuronal repair. For the treatment of diseases such as type I diabetes that requires insulin release regulated by the patient's metabolic needs, microencapsulation may be the most effective therapeutic strategy. However, new materials need to be developed, so that transplanted encapsulated cells are able to survive for longer periods in the host. In this article, we discuss microencapsulation strategies and chart recent progress in nanomedicine that offers new potential for this area in the future.

A general fruit acid chelation route for eco-friendly and ambient 3D printing of metals

Recent advances in metal additive manufacturing (AM) have provided new opportunities for prompt designs of prototypes and facile personalization of products befitting the fourth industrial revolution. In this regard, its feasibility of becoming a green technology, which is not an inherent aspect of AM, is gaining more interests. A particular interest in adapting and understanding of eco-friendly ingredients can set its important groundworks. Here, we demonstrate a water-based solid-phase binding agent suitable for binder jetting 3D printing of metals. Sodium salts of common fruit acid chelators form stable metal-chelate bridges between metal particles, enabling elaborate 3D printing of metals with improved strengths. Even further reductions in the porosity between the metal particles are possible through post-treatments. A compatibility of this chelation chemistry with variety of metals is also demonstrated. The proposed mechanism for metal 3D printing can open up new avenues for consumer-level personalized 3D printing of metals.

Aligned Stacking of Nanopatterned 2D Materials for High-Resolution 3D Device Fabrication

Two-dimensional materials can be combined by placing individual layers on top of each other, so that they are bound only by their van der Waals interaction. The sequence of layers can be chosen arbitrarily, enabling an essentially atomic-level control of the material and thereby a wide choice of properties along one dimension. However, simultaneous control over the structure in the in-plane directions is so far still rather limited. Here, we combine spatially controlled modifications of 2D materials, using focused electron irradiation or electron beam induced etching, with the layer-by-layer assembly of van der Waals heterostructures. The presented assembly process makes it possible to structure each layer with an arbitrary pattern prior to the assembly into the heterostructure. Moreover, it enables a stacking of the layers with accurate lateral alignment, with an accuracy of currently 10 nm, under observation in an electron microscope. Together, this enables the fabrication of almost arbitrary 3D structures with highest spatial resolution.

Stiffness control in dual color tomographic volumetric 3D printing

Tomographic volumetric printing (TVP) physically reverses tomography to offer fast and auxiliary-free 3D printing. Here we show that wavelength-sensitive photoresins can be cured using visible ([Formula: see text] nm) and UV ([Formula: see text] nm) sources simultaneously in a TVP setup to generate internal mechanical property gradients with high precision. We develop solutions of mixed acrylate and epoxy monomers and utilize the orthogonal chemistry between free radical and cationic polymerization to realize fully 3D stiffness control. The radial resolution of stiffness control is 300 µm or better and an average modulus gradient of 5 MPa/µm is achieved. We further show that the reactive transport of radical inhibitors defines a workpiece's shape and limits the achievable stiffness contrast to a range from 127 MPa to 201 MPa according to standard tensile tests after post-processing. Our result presents a strategy for controlling the stiffness of material spatially in light-based volumetric additive manufacturing.

Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses

3D printing has been considered as a sustainable method to construct complicated 3D structures. However, the step effect induced by the traditional point-by-point or layer-by-layer additive manufacturing mode inevitably occurs and remains an obstacle to realizing the smoothness and uniformity of 3D samples. Here, a continuous liquid film confined 3D printing strategy is proposed to fabricate high-precision 3D structures based on the Digital Light Processing (DLP) technology. With the control of the confinement of the liquid-solid interface and the continuous printing mode, liquid film adhering to the cured structure is sucked into the cured layer structures with excess resin adhering to the cured structure scraping off, where the step effect is eliminated and post-washing is avoided. The morphology and dimension of the confined liquid film can be well regulated by ink properties and printing parameters to optimize the surface smoothness and printing fidelity. In addition, heat accumulation and thermal diffusion are also suppressed, ensuring the long-term printing stability. A centimeter-scale contact lens structure with central thickness of ≈135 µm comparable to commercial ones can be printed, which possesses extreme smoothness (sub 1.3 nm), homogeneous mechanical characteristic, biocompatibility, and high optical properties with imaging resolution of up to 228.1 lp mm^-1 .

Quaternized Polydopamine Coatings for Anchoring Molecularly Dispersed Broad-Spectrum Antimicrobial Silver Salts

Because of the broad-spectrum antimicrobial efficacy, silver-based coatings have emerged as the popular choice to apply over frequently touched surfaces for mitigating the spread of nosocomial infections. Despite the advancements through various coating strategies, clustering of the active component remains a bottleneck in achieving the molecular-scale dispersion of silver. To circumvent this, the current study takes advantage of the recent findings of quaternary ammonium moieties forming molecular complexes with silver salts that differ from the simple adduct between the individual components. Here we demonstrate the quaternization of oxidatively cross-linked polydopamine coatings over magnetite nanoparticles to anchor ionic silver at a molecular-scale dispersion. The silver-derivatized materials exhibit remarkable broad-spectrum antimicrobial properties against representative microbes like E. coli, S. aureus, and A. niger. Also, the study reveals the materials' antibiofilm efficacy (∼80-90%) against both bacteria. Further recyclability studies have proven the sustained bactericidal properties up to five cycles. The surface derivatization strategy has then been extended to cover glass slips that have also shown the retention of the bactericidal properties even after wiping 20 times with artificial sweat. The biocompatibility of the materials has been ascertained with treated water against the mouse fibroblast and human embryonic kidney cell lines. The current study offers insights in developing coatings with molecular-scale dispersion of ionic silver to achieve broad-spectrum antimicrobial properties in an atom-economical and sustainable manner.

Facile fabrication of micro-/nanostructured, superhydrophobic membranes with adjustable porosity by 3D printing

Porous membranes with special wetting properties have attracted great interest due to their various functions and wide applications, including water filtration, selective oil/water separation and oil skimming. Special wetting properties such as superhydrophobicity can be achieved by controlling the surface chemistry as well as the surface topography of a substrate. Three-dimensional (3D) printing is a promising method for the fast and easy generation of various structures. The most common method for 3D printing of superhydrophobic materials is a two-step fabrication process: 3D printing of user-defined topographies, such as surface structures or bulk porosity, followed by a chemical post-processing with low-surface energy chemicals such as fluorinated silanes. Another common method is using a hydrophobic polymer ink to print intricate surface structures. However, the resolution of most common printers is not sufficient to produce nano-/microstructured textures, moreover, the resulting delicate surface micro- or nanostructures are very prone to abrasion. Herein, we report a simple approach for 3D printing of superhydrophobic micro-/nanoporous membranes in a single step, combining the required topography and chemistry. The bulk porosity of this material, which we term "Fluoropor", makes it insensitive to abrasion. To achieve this, a photocurable fluorinated resin is mixed with a porogen mixture and 3D printed using a stereolithography (SLA) printing process. This way, micro-/nanoporous membranes with superhydrophobic properties with static contact angles of 164° are fabricated. The pore size of the membranes can be adjusted from 30 nm to 300 nm by only changing the porogen ratio in the mixture. We show the applicability of the printed membranes for oil/water separation and the formation of Salvinia layers which are of great interest for drag reduction in maritime transportation and fouling prevention.

Superhydrophobic Polymer Composite Surfaces Developed via Photopolymerization

Fabrication of superhydrophobic materials using incumbent techniques involves several processing steps and is therefore either quite complex, not scalable, or often both. Here, the development of superhydrophobic surface-patterned polymer-TiO₂ composite materials using a simple, single-step photopolymerization-based approach is reported. The synergistic combination of concurrent, periodic bump-like pattern formation created using irradiation through a photomask and photopolymerization-induced nanoparticle (NP) phase separation enables the development of surface textures with dual-scale roughness (micrometer-sized bumps and NPs) that demonstrate high water contact angles, low roll-off angles, and desirable postprocessability such as flexibility, peel-and-stick capability, and self-cleaning capability. The effect of nanoparticle concentration on surface porosity and consequently nonwetting properties is discussed. Large-area fabrication over an area of 20 cm², which is important for practical applications, is also demonstrated. This work demonstrates the capability of polymerizable systems to aid in the organization of functional polymer-nanoparticle surface structures.

Lactobacillus amylovorus derived lipase-mediated silver derivatization over poly(ε-caprolactone) towards antimicrobial coatings

Owing to the probiotic origin, lipases-derived from the Lactobacilli sp. are considered to be promising biomaterials for in vivo applications. On a different note, poly(ε-caprolactone) (PCL)-an FDA-approved polymer for implantable applications-lacks inherent antimicrobial property, because of which suitable modifications are required to render it with bactericidal activity. Here, we employ Lactobacillus amylovorous derived lipase to surface derivatize the PCL films with silver that is a highly efficient inorganic broad-spectrum antimicrobial substance. Two different surface functionalization strategies have been employed over the alkaline hydrolyzed PCL films towards this purpose: In the first strategy, lipase-capped silver nanoparticles (Ag NPs) have been synthesized in a first step, which have been covalently immobilized over the activated carboxylic groups on the PCL film surface in a subsequent step. In the second strategy, the lipase was covalently immobilized over the activated carboxylic groups of the PCL film surface in the first step, over which silver was deposited in the second step using the dip-coating method. While the characterization study using X-ray photoelectron spectroscopy (XPS) has revealed the successful derivatization of silver over the PCL film, the surface characterization using field-emission scanning electron microscopy (FE-SEM) study has shown a distinct morphological change with higher silver loading in both strategies. The antimicrobial studies employing E. coli have revealed 100 % inhibition in the bacterial growth in 4-6 h with the Ag NPs-immobilized PCL films as opposed to >8 h with those prepared through the dip-coating method. Additionally, the cytotoxicity assay using mouse fibroblast cells has shown that the PCL films immobilized with lipase-capped Ag NPs exhibit high cell compatibility, similar to that of pristine PCL film, and thereby making it suitable for in vivo applications.

Correcting ray distortion in tomographic additive manufacturing

Light-based additive manufacturing techniques enable a rapid transition from object design to production. In these approaches, a 3D object is typically built by successive polymerization of 2D layers in a photocurable resin. A recently demonstrated technique, however, uses tomographic dose patterning to establish a 3D light dose distribution within a cylindrical glass vial of photoresin. Lensing distortion from the cylindrical vial is currently mitigated by either an index matching bath around the print volume or a cylindrical lens. In this work, we show that these hardware approaches to distortion correction are unnecessary. Instead, we demonstrate how the lensing effect can be computationally corrected by resampling the parallel-beam radon transform into an aberrated geometry. We also demonstrate a more general application of our computational approach by correcting for non-telecentricity inherent in most optical projection systems. We expect that our results will underpin a more simple and flexible class of tomographic 3D printers where deviations from the assumed parallel-beam projection geometry are rectified computationally.