Additive manufacturing of micro-architected metals via hydrogel infusion

Metal-Organic Decomposition for Additive Manufacturing of Extreme Environment Electronics

The lack of intrinsic resistance to oxidation and corrosion, particularly in high-temperature environments, significantly limits the performance and longevity of materials used in extreme conditions like aerospace and energy applications. A key challenge is developing single-step additive manufacturing capable of producing metals and ceramics with built-in resistance to these degradative processes. Herein, we report a metal-organic decomposition strategy to additively manufacture hybrid electronic materials that remain stable at 1100 °C for over 37 h and more than 80 h in strong acid and base solutions, demonstrating oxidation and corrosion resistance. The gold materials, derived from partial in-solution reduction and thermal decomposition of the precursor, exhibit a high conductivity of 10.8 MS/m at 1000 °C, while the molecular decomposed alumina shows a phase transformation from the γ-phase to the stable α-phase below 1000 °C. Synchrotron-based in situ wide-angle X-ray scattering (WAXS) was employed to analyze its crystal structure and high-temperature stability mechanistically. These findings suggest that the combination of molecular decomposed gold and alumina in a top-down structure (metal-ceramic) from molecular decomposition possesses great potential for extreme environment electronics with thermal stability and reliability, allowing wireless temperature detection in harsh environments from room temperature to 1000 °C.

3D Printing of Metal and Alloy Nanoarchitectures through a Complexation-Driven Strategy

3D metal/alloy nanoarchitectures demonstrate transformative potential for next-generation technologies including metamaterials, nanophotonics, and microrobotics. Current metal/alloy nanomanufacturing methods are often restricted to limited metals and simple geometries. Herein, we propose a versatile and scalable method for fabricating 3D metal-alloy nanoarchitectures through a complexation-driven strategy. By leveraging the complexation of metal ions with carboxyl groups, various metal ions are incorporated into acrylic acid-based polymer scaffolds. Subsequent thermal decomposition and reduction transform these scaffolds into metallic nanoarchitectures. As most metal ions can engage in complexation, we successfully fabricated seven distinct elemental metal nanoarchitectures and their corresponding alloy variants, substantiating the versatility of our method. This work establishes a scalable platform for nanoscale metal and alloy manufacturing, opening new possibilities for advanced nanoengineering applications.

Exploiting multiscale dynamic toughening in multicomponent alloy metamaterials for extreme impact mitigation

Mechanical metamaterials can unlock extreme properties by leveraging lightweight structural design principles and unique deformation mechanisms. However, research has predominantly focused on their quasi-static characteristics, leaving their behavior under extreme dynamic conditions, especially at length scales relevant to practical applications largely unexplored. Here, we present a strategy to achieve extreme impact mitigation at the macroscale by combining shell-based microarchitecture with an additively manufactured medium-entropy alloy (MEA) featuring low stacking fault energy (SFE). Notably, the shell-based architecture amplifies the effective dynamic stress within the metamaterial compared to truss-based morphologies, leading to the earlier activation of multiscale toughening mechanisms in the alloy. The low SFE of the MEA enables the evolution of a diverse array of defect types, thereby prolonging strain hardening behavior across seven orders of magnitude in strain rate. These fundamental insights could establish the groundwork for developing scalable, lightweight, impact-resistant metamaterials for structural and defense applications.

X-ray-Induced Photodegradation of Hydrogels by the Incorporation of X-ray-Activated Long Persistent Luminescent Nanoparticles

The development of on-demand degradable hydrogels remains an important challenge. Even though photodegradable hydrogels offer spatiotemporal control over degradation, it is difficult to use ultraviolet, visible, or near-infrared light as a tool for noninvasive triggering in vivo due to the poor tissue-penetration capacity. In contrast, X-ray irradiation can penetrate deep tissue and has virtually no penetration limitations for biological soft tissues. In this study, we propose an X-ray-photodegradation cascade system for hydrogel degradation by incorporating X-ray-activated persistent luminescence nanoparticles (X-PLNPs) into photodegradable hydrogels. A photodegradable 9,10-dialkoxyanthracene-based cross-linker was synthesized and used to prepare photodegradable hydrogels, of which the degradation behavior can be triggered by visible green light. Next, Tb3+-doped β-NaLuF4 was introduced as an X-PLNP that can convert X-rays into visible light centered at 544 nm. The afterglow can even be detected for 4 × 103 s after switching off the X-ray irradiation. The X-ray-induced green light emission was demonstrated to trigger photodegradation of the hydrogel. This proof-of-concept system for X-ray irradiation-induced on-demand hydrogel degradation was used to demonstrate X-ray-sensitive drug delivery inside a chicken breast as the in vitro tissue model. As this X-ray-induced cascade degradation of hydrogels can penetrate deep tissues, it is a promising platform for future in vivo applications requiring on-demand triggered hydrogel degradation, such as drug delivery or removal of hydrogel patches, hydrogel adhesives, or hydrogel tissue engineering scaffolds. It should, however, be noted that the hydrogel's X-ray and photoresponsiveness should be further improved to enable future in vivo use.

Transformative 3D Printing of Carbon-metal Nanocomposites as Catalytic Joule Heaters for Enhanced Ammonia Decomposition

Electrified thermal chemical synthesis plays a critical role in reducing energy consumption and enabling the industrial decarbonization. While Joule heating offers a promising alternative to gas-burning furnace systems by directly heating substrates via renewable energy supply, most approaches can only heat the reactor, not the catalytic sites. This limitation stems from the lack of methods to on-demand create Joule heaters containing in situ loaded catalytic nanoparticles. This work introduces a scalable platform for producing carbonaceous Joule heaters embedded with catalytic nanoparticles from 3D-printed polypropylene precursors, prepared through crosslinking, metal nitration immersion, and pyrolysis steps. Specifically, sulfonate groups on crosslinked PP can bind with metal ions, yielding well-dispersed, nanosized particles within a carbon structure that maintains macroscopic dimensional accuracy throughout the manufacturing. The approach is modular, allowing control over particle size and composition. Structured carbon with in situ loaded nickel nanoparticles demonstrates efficient Joule heating, high catalytic activity, and significantly reduced activation energy for catalytic ammonia decomposition. This work provides an innovative material and manufacturing platform to produce structured, catalytically active Joule heaters for decarbonization of chemical synthesis and energy production.

Enabling three-dimensional architected materials across length scales and timescales

Architected materials provide a pathway to defy the limitations of monolithic materials through their engineered microstructures or geometries, allowing them to exhibit unique and extreme properties. Thus far, most studies on architected materials have been limited to fabricating periodic structures in small tessellations and investigating them under mostly quasi-static conditions, but explorations of more complex architecture designs and their properties across length scales and timescales will be essential to fully uncover the potential of this materials system. In this Perspective, we summarize state-of-the-art approaches to realizing multiscale architected materials and highlight existing knowledge gaps and opportunities in their design, fabrication and characterization. We also propose a roadmap to accelerate the discovery of architected materials with programmable properties via the synergistic combination of experimental and computational efforts. Finally, we identify research opportunities and open questions in the development of next-generation architected materials, intelligent devices and integrated systems that can bridge the gap between the conception and implementation of these materials in real-world engineering applications.

3D-AJP: Fabrication of Advanced Microarchitected Multimaterial Ceramic Structures via Binder-Free and Auxiliary-Free Aerosol Jet 3D Nanoprinting

Manufacturing of ceramics is challenging due to their low toughness and high hardness. Additive Manufacturing (AM) has been explored to create complex ceramic structures, but current techniques face a tradeoff between precisely controlled feature sizes and high shrinkage at the microscales. Here, we introduce 3D-AJP, a novel freeform ceramic fabrication method that enables highly complex microscale 3D ceramic architectures-such as micropillars, spirals, and lattices-with minimal shrinkage and no auxiliary support. Using a near-binder-free nanoparticle ink in an Aerosol Jet (AJ) 3D printer, our approach precisely controls feature sizes down to 20 µm with aspect ratios up to 30:1. The resulting structures exhibit exceptionally low linear shrinkage of 2-6% upon sintering, spanning five orders of magnitude in length scale. Bi-material 3D architectures (zinc oxide/zirconia, zinc oxide/titania, titania/zirconia) and hybrid ceramics further demonstrate the technique's versatility. We showcase two key applications. First, 3D ceramic photocatalysts improve water purification performance, achieving a 400% increase in photocatalytic efficiency compared to bulk ceramics. Second, we develop a highly sensitive Her2 biomarker sensor for breast cancer detection, achieving a 22-second response time and a record-low detection limit of 0.0193 fm. Our technique will lead to high-performance sensing, filtration, microelectronics packaging, catalysis, and tissue regeneration technologies.

Recent Advances in 3D Printed Electrodes - Bridging the Nano to Mesoscale

3D architected electrodes offer inherent physicochemical advantages for energy storage, conversion, and sensing. 3D printing methods such as stereolithography and two photon polymerization are uniquely capable of fabricating these architected electrodes with a high degree of geometric complexity impossible to achieve with other methods at the mesoscale (10 µm-1 mm). The material set for 3D printing traditionally is focused on structural materials rather than functional materials suitable for electronic and electrochemical applications. In this review the fundamental challenges are considered for transforming 3D printed materials into conductive, multifunctional electrodes suitable for electrical and electrochemical devices by printing nanocomposites, infusing molecular precursors and post-processing these structures via carbonization. To understand the design of 3D electrodes toward their use in both sensors and electrochemical devices such as catalysts, this review summarizes recent advances in hierarchical design of porous metastructures, the engineering of mass transport and electronic transport in 3D structures, and the application of high-throughput materials design by machine learning and artificial intelligence. These emerging approaches to 3D electrode design and architecture promise to expand the capabilities of additive manufacturing beyond structural materials and bring its advantages to bear on modern devices such as sensors, batteries, supercapacitors, and electrocatalysts.

Additive manufacturing of water-soluble 3D micro molds for complex-shaped lipid microparticles

Micro and nanoparticles made from polymers, metals, ceramics, and lipids are crucial for biomedical devices, energy storage, and electronics. Traditional fabrication methods like grinding, milling, and emulsification result in monolithic shapes and heterogeneous sizes. To improve shape control, techniques such as photolithography, inkjet printing (IJP), and molding are employed. Water-soluble molds are particularly promising for materials with solvent incompatibility, thermolability, and poor mechanical properties. Among them, lipids are interesting for their use in biomedical applications, however, current fabrication methods limit lipid microparticles to monolithic spherical shapes. This study presents calcium-based water-soluble 3D micro molds fabricated using two-photon polymerization (TPP) for complex-shaped lipid microparticles. TPP-fabricated organogels are converted to hydrogels, loaded with calcium nitrate, and calcined into Ca-based materials. Lipids are infiltrated into PVA-coated Ca-based molds via IJP, and selective mold leaching in water creates lipid microparticles with 2 µm resolution. The lipid microparticles can encapsulate and release lipophilic and hydrophilic drugs.

Laser-driven proton acceleration beyond 100 MeV by radiation pressure and Coulomb repulsion in a conduction-restricted plasma

An ultrahigh-intensity femtosecond laser can establish a longitudinal electric field stronger than 1013 Vm-1 within a plasma, accelerating particles potentially to GeV over a sub-millimetre distance. Laser-accelerated protons with high brightness and picosecond duration are highly desired for applications including proton imaging and flash radiotherapy, while a major limitation is the relatively low proton energy achieved yet, primarily due to the lack of a controllable acceleration structure. Here, we report the generation of protons with a cutoff energy exceeding 110 MeV, achieved by irradiating a multi-petawatt femtosecond laser on a conduction-restricted nanometre polymer foil with a finite lateral size. The enduring obstacles in achieving ultrahigh laser contrast and excellent laser pointing accuracy were successfully overcome, allowing the effective utilization of size-reduced nanometre foils. A long acceleration structure could be maintained in such a quasi-isolated foil since the conduction of cold electrons was restricted and a strong Coulomb field was established by carbon ions. Our achievement paves the road to enhance proton energy further, well meeting the requirements for applications, through a controllable acceleration process using well-designed nano- or micro-structured targets.

From Single to Multi-Material 3D Printing of Glass-Ceramics for Micro-Optics

Feynman's statement, "There is plenty of room at the bottom", underscores vast potential at the atomic scale, envisioning microscopic machines. Today, this vision extends into 3D space, where thousands of atoms and molecules are volumetrically patterned to create light-driven technologies. To fully harness their potential, 3D designs must incorporate high-refractive-index elements with exceptional mechanical and chemical resilience. The frontier, however, lies in creating spatially patterned micro-optical architectures in glass and ceramic materials of dissimilar compositions. This multi-material capability enables novel ways of shaping light, leveraging the interaction between diverse interfaced chemical compositions to push optical boundaries. Specifically, it encompasses both multi-material integration within the same architectures and the use of different materials for distinct architectural features in an optical system. Integrating fluid handling systems with two-photon lithography (TPL) provides a promising approach for rapidly prototyping such complex components. This review examines single and multi-material TPL processes, discussing photoresin customization, essential physico-chemical conditions, and the need for cross-scale characterization to assess optical quality. It reflects on challenges in characterizing multi-scale architectures and outlines advancements in TPL for both single and spatially patterned multi-material structures. The roadmap provides a bridge between research and industry, emphasizing collaboration and contributions to advancing micro-optics.

Multi-Physical Lattice Metamaterials Enabled by Additive Manufacturing: Design Principles, Interaction Mechanisms, and Multifunctional Applications

Lattice metamaterials emerge as advanced architected materials with superior physical properties and significant potential for lightweight applications. Recent developments in additive manufacturing (AM) techniques facilitate the manufacturing of lattice metamaterials with intricate microarchitectures and promote their applications in multi-physical scenarios. Previous reviews on lattice metamaterials have largely focused on a specific/single physical field, with limited discussion on their multi-physical properties, interaction mechanisms, and multifunctional applications. Accordingly, this article critically reviews the design principles, structure-mechanism-property relationships, interaction mechanisms, and multifunctional applications of multi-physical lattice metamaterials enabled by AM techniques. First, lattice metamaterials are categorized into homogeneous lattices, inhomogeneous lattices, and other forms, whose design principles and AM processes are critically discussed, including the benefits and drawbacks of different AM techniques for fabricating different types of lattices. Subsequently, the structure-mechanism-property relationships and interaction mechanisms of lattice metamaterials in a range of physical fields, including mechanical, acoustic, electromagnetic/optical, and thermal disciplines, are summarized to reveal critical design principles. Moreover, the multifunctional applications of lattice metamaterials, such as sound absorbers, insulators, and manipulators, sensors, actuators, and soft robots, thermal management, invisible cloaks, and biomedical implants, are enumerated. These design principles and structure-mechanism-property relationships provide effective design guidelines for lattice metamaterials in multifunctional applications.

Recent innovations in interfacial strategies for DLP 3D printing process optimization

Three-dimensional (3D) printing, also known as additive manufacturing, is capable of transforming computer-aided designs into intricate structures directly and on demand. This technology has garnered significant attention in recent years. Among the various approaches, digital light processing (DLP) 3D printing, which utilizes polymers or prepolymers as the ink, has emerged as the leading new technology, driven by high demand across diverse fields such as customized production, healthcare, education, and art design. DLP 3D printing technology employs cured slices as molding units and is recognized for its potential to achieve both high printing speed and resolution. Recent insights into the DLP printing process highlight its inherent interface transformations between liquid and solid states. This review summarizes key aspects of the printing process, speed, precision, and material diversity optimization, from the view of interfacial interactions between solid and liquid phases which are influenced by resin formation, curing surfaces and light source properties. These interactions include those at the liquid resin-UV pattern interface, the cured structure-curing surface interface, the liquid resin-curing surface interface, and the liquid resin-cured structure interface, each contributing to the unique characteristics of the printed results. Finally, this review addresses the current challenges and limitations of DLP 3D printing, providing valuable insights for future improvements and guiding potential innovations in the field.

Multiphoton and Harmonic Imaging of Microarchitected Materials

Microadditive manufacturing has revolutionized the production of complex, nano- to microscale components across various fields. This work investigates two-photon (2P) and three-photon (3P) fluorescence imaging, as well as third-harmonic generation (THG) microscopy, to examine periodic microarchitected lattice structures fabricated using multiphoton lithography (MPL). By immersing the structures in refractive index matching fluids, we demonstrate high-fidelity 3D reconstructions of both fluorescent structures using 2P and 3P microscopy as well as low-fluorescence structures using THG microscopy. These results show that multiphoton fluorescence (MPF) imaging offers reduced signal decay with respect to depth compared to single-photon techniques in the examined structures. We further demonstrate the ability to nondestructively identify intentional internal modifications of the structure that are not immediately visible with scanning electron microscope (SEM) images and compression-induced fractures, highlighting the potential of these techniques for quality control and defect detection in microadditively manufactured components.

Photocurable Sol-Gel Formulations for the Fabrication of Titanium Carbide/Carbon Nanocomposites via Digital Light Processing

Additive manufacturing of carbide materials has received significant attention in the past years due to the ability to fabricate complex structures over different length scales. However, the typical limitations for powder-laden inks, such as nozzle clogging, rheological and geometric constraints, particle sedimentation, light-scattering and absorbing phenomena, narrow the range of available processes to manufacture carbide materials via conventional particle-based systems. To address these shortcomings, we have developed a one-pot synthetic route for the preparation of sol-gel-based UV-photocurable formulations, aiming at the fabrication of titanium carbide/carbon nanocomposites using digital light processing printing, pointing to potential applications in the field of nuclear physics. Carbides have attracted increasing interest as a target material for the production of radioisotopes in the ISOL facilities; however, the release of radioisotopes strictly relies on the presence of open porous structures, thus enhancing the diffusion and effusion phenomena from the target component. Through our approach, we have successfully fabricated hierarchical porous structures of TiC with a high specific surface area. By controlling the positioning of the building blocks within the framework and the supramolecular interactions during the polymerization of the molecular precursors, we achieved multiscale structuring of the network with precise control over the local arrangement of the pores.

Printing of 3D photonic crystals in titania with complete bandgap across the visible spectrum

A photonic bandgap is a range of wavelengths wherein light is forbidden from entering a photonic crystal, similar to the electronic bandgap in semiconductors. Fabricating photonic crystals with a complete photonic bandgap in the visible spectrum presents at least two important challenges: achieving a material refractive index > ~2 and a three-dimensional patterning resolution better than ~280 nm (lattice constant of 400 nm). Here we show an approach to overcome such limitations using additive manufacturing, thus realizing high-quality, high-refractive index photonic crystals with size-tunable bandgaps across the visible spectrum. We develop a titanium ion-doped resin (Ti-Nano) for high-resolution printing by two-photon polymerization lithography. After printing, the structures are heat-treated in air to induce lattice shrinkage and produce titania nanostructures. We attain three-dimensional photonic crystals with patterning resolution as high as 180 nm and refractive index of 2.4-2.6. Optical characterization reveals ~100% reflectance within the photonic crystal bandgap in the visible range. Finally, we show capabilities in defining local defects and demonstrate proof-of-principle applications in spectrally selective perfect reflectors and chiral light discriminators.

Design and Application of Joule Heating Processes for Decarbonized Chemical and Advanced Material Synthesis

Atmospheric CO2 concentrations keep increasing at intensifying rates due to rising energy and material demands. The chemical production industry is a large energy consumer, responsible for up to 935 Mt of CO2 emissions per year, and decarbonization is its major goal moving forward. One of the primary sources of energy consumption and CO2 emissions in the chemical sector is associated with the production and use of heat for material synthesis, which conventionally was generated through the combustion of fossil fuels. To address this grand challenge, Joule heating has emerged as an alternative heating method that greatly increases process efficiency, reducing both energy consumption and greenhouse gas emissions. In this Review, we discuss the key concepts that govern these Joule heating processes including material selection and reactor design, as well as the current state-of-the-art in the literature for employing these processes to synthesize commodity chemicals along with advanced materials such as graphene, metal species, and metal carbides. Finally, we provide a perspective on future research avenues within this field, which can facilitate the widespread adoption of Joule heating for decarbonizing industrial processes.

Meta-structure of amorphous-inspired 65.1Co28.2Cr5.3Mo lattices augmented by artificial intelligence

A hatching-distance-controlled lattice of 65.1Co28.2Cr5.3Mo is additively manufactured via laser powder bed fusion with a couple of periodic and aperiodic arrangements of nodes and struts. Thus, the proposed lattice has an amorphous-inspired structure in the short- and long-range orders. From the structural perspective, an artificial intelligence algorithm is used to effectively align lattices with various hatching distances. Then, the metastable lattice combination exhibits an unexpectedly high specific compression strength that is only slightly below that of a solid structure. From the microstructural perspective, the nodes in the newly designed lattice, where the thermal energy from laser irradiation is mainly concentrated, exhibit an equiaxial microstructure. By contrast, the struts exhibit a columnar microstructure, thereby allowing the thermal energy to pass through the narrow ligaments. The heterogeneous phase differences between the nodal and strut areas explain the strength-deteriorating mechanism, owing to the undesirable multi-phase development in the as-built state. However, solid-solution heat treatment to form a homogeneous phase bestows even higher specific compression strength. Furthermore, electrochemical leaching leads to the formation of nanovesicles on the surface of the microporous lattice system, thereby leading to a large surface area. A more advanced valve cage for use in a power plant is designed by using artificial intelligence both to (i) effectively preserve its mechanical stiffness and (ii) actively dissipate the generated stress through the large surface area provided by the nanovesicles.

Supplementary Information

The online version contains supplementary material available at 10.1007/s42114-024-01039-6.

Oriented cellulose hydrogel: Directed tissue regeneration for reducing corneal leukoplakia and managing fungal corneal ulcers

Fungal corneal ulcer is one of the leading causes of corneal blindness in developing countries. Corneal scars such as leukoplakia are formed due to inflammation, oxidative stress and non-directed repair, which seriously affect the patients' subsequent visual and life quality. In this study, drawing inspiration from the oriented structure of collagen fibers within the corneal stroma, we first proposed the directional arrangement of CuTA-CMHT hydrogel system at micro and macro scales based on the 3D printing extrusion method combined with secondary patterning. It played an antifungal role and induced oriented repair in therapy of fungal corneal ulcer. The results showed that it effectively inhibited Candida albicans, Aspergillus Niger, Fusarium sapropelum, which mainly affects TNF, NF-kappa B, and HIF-1 signaling pathways, achieving effective antifungal functions. More importantly, the fibroblasts interacted with extracellular matrix (ECM) of corneal stroma through formation of focal adhesions, promoted the proliferation and directional migration of cells in vitro, induced the directional alignment of collagen fibers and corneal stromal orthogonally oriented repair in vivo. This process is mainly associated with MYLK, MYL9, and ITGA3 molecules. Furthermore, the downregulation the growth factors TGF-β and PDGF-β inhibits myofibroblast development and reduces scar-type ECM production, thereby reducing corneal leukoplakia. It also activates the PI3K-AKT signaling pathway, promoting corneal healing. In conclusion, the oriented CuTA-CMHT hydrogel system mimics the orthogonal arrangement of collagen fibers, inhibits inflammation, eliminates reactive oxygen species, and reduces corneal leukoplakia, which is of great significance in the treatment of fungal corneal ulcer and is expected to write a new chapter in corneal tissue engineering.

Photoresist Development for 3D Printing of Conductive Microstructures via Two-Photon Polymerization

The advancement of electronic devices necessitates the development of three-dimensional (3D) high-precision conductive microstructures, which have extensive applications in bio-electronic interfaces, soft robots, and electronic skins. Two-photon polymerization (TPP) based 3D printing is a critical technique that offers unparalleled fabrication resolution in 3D space for intricate conductive structures. While substantial progress has been made in this field, this review summarizes recent advances in the 3D printing of conductive microstructures via TPP, mainly focusing on the essential criteria of photoresist resins suitable for TPP. Further preparation strategies of these photoresists and methods for constructing 3D conductive microstructures via TPP are discussed. The application prospects of 3D conductive microstructures in various fields are discussed, highlighting the imperative to advance their additive manufacturing technology. Finally, strategic recommendations are offered to enhance the construction of 3D conductive microstructures using TPP, addressing prevailing challenges and fostering significant advancements in manufacturing technology.

Ultra-high precision nano additive manufacturing of metal oxide semiconductors via multi-photon lithography

As a basic component of the versatile semiconductor devices, metal oxides play a critical role in modern electronic information industry. However, ultra-high precision nanopatterning of metal oxides often involves multi-step lithography and transfer process, which is time-consuming and costly. Here, we report a strategy, using metal-organic compounds as solid precursor photoresist for multi-photon lithography and post-sintering, to realize ultra-high precision additive manufacturing of metal oxides. As a result, we gain metal oxides including ZnO, CuO and ZrO2 with a critical dimension of 35 nm, which sets a benchmark for additive manufacturing of metal oxides. Besides, atomic doping can be easily accomplished by including the target element in precursor photoresist, and heterogeneous structures can also be created by multiple multi-photon lithography, allowing this strategy to accommodate the requirements of various semiconductor devices. For instance, we fabricate an ZnO photodetector by the proposed strategy.

Remarkable Dielectric Breakdown Strength of Printable Polyelectrolyte Photopolymer Complexes

Polymer-based dielectrics are struggling to keep pace with the increasing demands of modern electronics. This lag in dielectric performance has spurred significant interest in the production of advanced dielectrics via novel chemistries and processing techniques. Polyelectrolyte complexes (PECs) have recently shown great promise as dielectric insulation, but processing challenges presented by these ionically bound networks limit their use to conformal thin films. Recent advances have enabled the additive manufacturing of PECs with vat photopolymerization, allowing the creation of a polyelectrolyte complex of arbitrary shape. Herein, multiple polyelectrolyte resin formulations, comprised of polyethylenimine and methacrylic acid (with varying amounts of 2-hydroxyethyl methacrylate and/or N,N-dimethylacrylamide), are investigated for the production of additively manufactured dielectric insulators. These dielectrics not only possess high dielectric breakdown strengths (>300 kV/mm), but their dielectric behavior can also be readily tailored through resin formulation and post-processing conditions. The presented vat photopolymerization of PECs allows for the creation of bulk dielectrics with arbitrary geometry, while the novel chemistry provides a practical route forward to produce dielectrics with precisely tailored properties for specific applications.

Fabrication of High-Density Microarchitected Tungsten via DLP 3D Printing

Current additive manufacturing (AM) techniques for tungsten, such as powder bed fusion and directed energy deposition, often generate parts with rough surfaces. Vat photopolymerization presents a promising alternative for fabricating tungsten structures with high shape fidelity and low surface roughness. However, existing vat photopolymerization approaches suffer from surface defects and low final density, leading to compromised mechanical properties. Therefore, achieving high-density tungsten structures using vat photopolymerization remains a crucial challenge. This work presents a straightforward and reliable method for fabricating complex, micro-architected tungsten structures with superior density and hardness. The approach utilizes a water-based photoresin with exceptional tungsten ion loading capacity. The photoresin is then patterned using digital light processing (DLP) to create tungsten-laden precursors. A three-step debinding and sintering process subsequently achieves 3D tungsten structures with dense surface morphology and minimal internal defects. The microstructures achieve a minimum feature size of 35 µm, a low surface roughness of 2.86 µm, and demonstrate exceptional mechanical properties. This new method for structuring tungsten opens doors to a broad range of applications, including micromachining, collimators, detectors, and metamaterials.

Mechanical Regulation of Polymer Gels

The mechanical properties of polymer gels devote to emerging devices and machines in fields such as biomedical engineering, flexible bioelectronics, biomimetic actuators, and energy harvesters. Coupling network architectures and interactions has been explored to regulate supportive mechanical characteristics of polymer gels; however, systematic reviews correlating mechanics to interaction forces at the molecular and structural levels remain absent in the field. This review highlights the molecular engineering and structural engineering of polymer gel mechanics and a comprehensive mechanistic understanding of mechanical regulation. Molecular engineering alters molecular architecture and manipulates functional groups/moieties at the molecular level, introducing various interactions and permanent or reversible dynamic bonds as the dissipative energy. Molecular engineering usually uses monomers, cross-linkers, chains, and other additives. Structural engineering utilizes casting methods, solvent phase regulation, mechanochemistry, macromolecule chemical reactions, and biomanufacturing technology to construct and tailor the topological network structures, or heterogeneous modulus compositions. We envision that the perfect combination of molecular and structural engineering may provide a fresh view to extend exciting new perspectives of this burgeoning field. This review also summarizes recent representative applications of polymer gels with excellent mechanical properties. Conclusions and perspectives are also provided from five aspects of concise summary, mechanical mechanism, biofabrication methods, upgraded applications, and synergistic methodology.

Capillary trapping of various nanomaterials on additively manufactured scaffolds for 3D micro-/nanofabrication

High-precision additive manufacturing technologies, such as two-photon polymerization, are mainly limited to photo-curable polymers and currently lacks the possibility to produce multimaterial components. Herein, we report a physically bottom-up assembly strategy that leverages capillary force to trap various nanomaterials and assemble them onto three-dimensional (3D) microscaffolds. This capillary-trapping strategy enables precise and uniform assembly of nanomaterials into versatile 3D microstructures with high uniformity and mass loading. Our approach applies to diverse materials irrespective of their physiochemical properties, including polymers, metals, metal oxides, and others. It can integrate at least four different material types into a single 3D microstructure in a sequential, layer-by-layer manner, opening immense possibilities for tailored functionalities on demand. Furthermore, the 3D microscaffolds are removable, facilitating the creation of pure material-based 3D microstructures. This universal 3D micro-/nanofabrication technique with various nanomaterials enables the creation of advanced miniature devices with potential applications in multifunctional microrobots and smart micromachines.

3D Nanoprinting of Heterogeneous Metal Oxides with High Shape Fidelity

3D nanoprinting can significantly enhance the performance of sensors, batteries, optoelectronic/microelectronic devices, etc. However, current 3D nanoprinting methods for metal oxides are suffering from three key issues including limited material applicability, serious shape distortion, and the difficulty of heterogeneous integration. This paper discovers a mechanism in which imidazole and acrylic acid synergistically coordinate with metal ions in water. Using the mechanism, this work develops a series of metal ion synergistic coordination water-soluble (MISCWS) resins for 3D nanoprinting of various metal oxides, including MnO2, Cr2O3, Co3O4, and ZnO, as well as heterogeneous structures of MnO2/NiO, Cr2O3/Al2O3, and ZnO/MgO. Besides, the synergistic coordination effect results in a 2.54-fold increase in inorganic mass fraction within the polymer, compared with previous works, which effectively mitigates the shape distortion of metal oxide microstructures. Based on this method, this work also demonstrates a 3D ZnO microsensor with a high sensitivity (1.113 million at 200 ppm NO2), surpassing the conventional 2D ZnO sensors by tenfold. The method yields high-fidelity 3D structures of heterogeneous metal oxides with nanoscale resolution, paving the way for applications such as sensing, micro-optics, energy storage, and microsystems.

Bridging papermaking and hydrogel production: Nanoparticle-loaded cellulosic hollow fibers with pitted walls as skeleton materials for multifunctional electromagnetic hydrogels

Electromagnetic hydrogels have attracted significant attention due to their vast potential in soft robotics, biomedical engineering, and energy harvesting. To facilitate future commercialization via large-scale industrial processes, we present a facile concept that utilizes the specialized knowledge of papermaking to fabricate hydrogels with multifunctional electromagnetic properties. The principles of papermaking wet end chemistry, which involves the handling of interactions among cellulosic fibers, fines, polymeric additives, and other components in aqueous systems, serves as a key foundation for this concept. Notably, based on these principles, the versatile use of chemical additives in combination with cellulosic materials enables the tailored design of various products. Our methodology exploits the unique hierarchically pitted and hollow tube-like structures of papermaking grade cellulosic fibers with discernible pits, enabling the incorporation of magnetite nanoparticles through lumen loading. By combining microscale softwood-derived cellulosic fibers with additives, we achieve dynamic covalent interactions that transform the cellulosic fiber slurry into an impressive hydrogel. The cellulosic fibers act as a skeleton, providing structural support within the hydrogel framework and facilitating the dispersion of nanoparticles. In accordance with our concept, the typical hydrogel exhibits combined attributes, including electrical conductivity, self-healing properties, pH responsiveness, and dynamic rheologic behavior. Our approach not only yields hydrogels with interesting properties but also aligns with the forefront of advanced cellulosic material applications. These materials hold the promise in remote strain sensing devices, electromagnetic navigation systems, contactless toys, and flexible electronic devices. The concept and findings of the current work may shed light on materials innovation based on traditional pulp and paper processes. Furthermore, the facile processes involved in hydrogel formation can serve as valuable tools for chemistry and materials education, providing easy demonstrations of principles for university students at different levels.

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.

Additive Manufacturing Provides Infinite Possibilities for Self-Sensing Technology

Integrating sensors and other functional parts in one device can enable a new generation of integrated intelligent devices that can perform self-sensing and monitoring autonomously. Applications include buildings that detect and repair damage, robots that monitor conditions and perform real-time correction and reconstruction, aircraft capable of real-time perception of the internal and external environment, and medical devices and prosthetics with a realistic sense of touch. Although integrating sensors and other functional parts into self-sensing intelligent devices has become increasingly common, additive manufacturing has only been marginally explored. This review focuses on additive manufacturing integrated design, printing equipment, and printable materials and stuctures. The importance of the material, structure, and function of integrated manufacturing are highlighted. The study summarizes current challenges to be addressed and provides suggestions for future development directions.

A bioinspired surface tension-driven route toward programmed cellular ceramics

The intriguing biomineralization process in nature endows the mineralized biological materials with intricate microarchitected structures in a facile and orderly way, which provides an inspiration for processing ceramics. Here, we propose a simple and efficient manufacturing process to fabricate cellular ceramics in programmed cell-based 3D configurations, inspired by the biomineralization process of the diatom frustule. Our approach separates the ingredient synthesis from architecture building, enabling the programmable manufacturing of cellular ceramics with various cell sizes, geometries, densities, metastructures, and constituent elements. Our approach exploits surface tension to capture precursor solutions in the architected cellular lattices, allowing us to control the liquid geometry and manufacture cellular ceramics with high precision. We investigate the geometry parameters for the architected lattices assembled by unit cells and unit columns, both theoretically and experimentally, to guide the 3D fluid interface creation in arranged configurations. We manufacture a series of globally cellular and locally compact piezoceramics, obtaining an enhanced piezoelectric constant and a designed piezoelectric anisotropy. This bioinspired, surface tension-assisted approach has the potential to revolutionize the design and processing of multifarious ceramic materials for structural and functional applications in energy, electronics and biomedicine.

Additive Manufacturing of Micro-Architected Copper based on an Ion-Exchangeable Hydrogel

Additive manufacturing (AM) of copper through laser-based processes poses challenges, primarily attributed to the high thermal conductivity and low laser absorptivity of copper powder or wire as the feedstock. Although the use of copper salts in vat photopolymerization-based AM techniques has garnered recent attention, achieving micro-architected copper with high conductivity and density has remained elusive. In this study, we present a facile and efficient process to create complex 3D micro-architected copper structures with superior electrical conductivity and hardness. The process entails the formulation of an ion-exchangeable photoresin, followed by the utilization of digital light processing (DLP) printing to sculpt 3D hydrogel scaffolds, which were transformed into Cu2+-chelated polymer frameworks (Cu-CPFs) with a high loading of Cu2+ ions through ion exchange, followed by debinding and sintering, results in the transformation of Cu-CPFs into miniaturized copper architectures. This methodology represents an efficient pathway for the creation of intricate micro-architected 3D metal structures.

Hydrogel-Reactive-Microenvironment Powering Reconfiguration of Polymer Architectures

Reconfiguration of architected structures has great significance for achieving new topologies and functions of engineering materials. Existing reconfigurable strategies have been reported, including approaches based on heat, mechanical instability, swelling, origami/kirigami designs, and electromagnetic actuation. However, these approaches mainly involve physical interactions between the host materials and the relevant stimuli. Herein, a novel, easy-manipulated, and controllable reconfiguration strategy for polymer architectures is proposed by using a chemical reaction of host material within a hydrogel reactive microenvironment. 3D printed polycaprolactone (PCL) lattices transformed in an aqueous polyacrylamide (PAAm) hydrogel precursor solution, in which ultraviolet (UV) light triggered heterogeneous grafting polymerization between PCL and AAm. In situ microscopy shows that PCL beams go through volumetric expansion and cooperative buckling, resulting in transformation of PCL lattices into sinusoidal patterns. The transformation process can be tuned easily and patterned through the adjustment of the PCL beam diameter, unit cell width, and UV light on-off state. Controlling domain formation is achieved by using UV masks. This framework enables the design, fabrication, and programming of architected materials and inspires the development of novel 4D printing approaches.

Pretreatment-free SERS sensing of microplastics using a self-attention-based neural network on hierarchically porous Ag foams

Low-cost detection systems are needed for the identification of microplastics (MPs) in environmental samples. However, their rapid identification is hindered by the need for complex isolation and pre-treatment methods. This study describes a comprehensive sensing platform to identify MPs in environmental samples without requiring independent separation or pre-treatment protocols. It leverages the physicochemical properties of macroporous-mesoporous silver (Ag) substrates templated with self-assembled polymeric micelles to concurrently separate and analyze multiple MP targets using surface-enhanced Raman spectroscopy (SERS). The hydrophobic layer on Ag aids in stabilizing the nanostructures in the environment and mitigates biofouling. To monitor complex samples with multiple MPs and to demultiplex numerous overlapping patterns, we develop a neural network (NN) algorithm called SpecATNet that employs a self-attention mechanism to resolve the complex dependencies and patterns in SERS data to identify six common types of MPs: polystyrene, polyethylene, polymethylmethacrylate, polytetrafluoroethylene, nylon, and polyethylene terephthalate. SpecATNet uses multi-label classification to analyze multi-component mixtures even in the presence of various interference agents. The combination of macroporous-mesoporous Ag substrates and self-attention-based NN technology holds potential to enable field monitoring of MPs by generating rich datasets that machines can interpret and analyze.

Control of polymers' amorphous-crystalline transition enables miniaturization and multifunctional integration for hydrogel bioelectronics

Soft bioelectronic devices exhibit motion-adaptive properties for neural interfaces to investigate complex neural circuits. Here, we develop a fabrication approach through the control of metamorphic polymers' amorphous-crystalline transition to miniaturize and integrate multiple components into hydrogel bioelectronics. We attain an about 80% diameter reduction in chemically cross-linked polyvinyl alcohol hydrogel fibers in a fully hydrated state. This strategy allows regulation of hydrogel properties, including refractive index (1.37-1.40 at 480 nm), light transmission (>96%), stretchability (139-169%), bending stiffness (4.6 ± 1.4 N/m), and elastic modulus (2.8-9.3 MPa). To exploit the applications, we apply step-index hydrogel optical probes in the mouse ventral tegmental area, coupled with fiber photometry recordings and social behavioral assays. Additionally, we fabricate carbon nanotubes-PVA hydrogel microelectrodes by incorporating conductive nanomaterials in hydrogel for spontaneous neural activities recording. We enable simultaneous optogenetic stimulation and electrophysiological recordings of light-triggered neural activities in Channelrhodopsin-2 transgenic mice.

4D printing for biomedical applications

While three-dimensional (3D) printing excels at fabricating static constructs, it fails to emulate the dynamic behavior of native tissues or the temporal programmability desired for medical devices. Four-dimensional (4D) printing is an advanced additive manufacturing technology capable of fabricating constructs that can undergo pre-programmed changes in shape, property, or functionality when exposed to specific stimuli. In this Perspective, we summarize the advances in materials chemistry, 3D printing strategies, and post-printing methodologies that collectively facilitate the realization of temporal dynamics within 4D-printed soft materials (hydrogels, shape-memory polymers, liquid crystalline elastomers), ceramics, and metals. We also discuss and present insights about the diverse biomedical applications of 4D printing, including tissue engineering and regenerative medicine, drug delivery, in vitro models, and medical devices. Finally, we discuss the current challenges and emphasize the importance of an application-driven design approach to enable the clinical translation and widespread adoption of 4D printing.

Roll-to-roll, high-resolution 3D printing of shape-specific particles

Particle fabrication has attracted recent attention owing to its diverse applications in bioengineering1,2, drug and vaccine delivery3-5, microfluidics6,7, granular systems8,9, self-assembly5,10,11, microelectronics12,13 and abrasives14. Herein we introduce a scalable, high-resolution, 3D printing technique for the fabrication of shape-specific particles based on roll-to-roll continuous liquid interface production (r2rCLIP). We demonstrate r2rCLIP using single-digit, micron-resolution optics in combination with a continuous roll of film (in lieu of a static platform), enabling the rapidly permutable fabrication and harvesting of shape-specific particles from a variety of materials and with complex geometries, including geometries not possible to achieve with advanced mould-based techniques. We demonstrate r2rCLIP production of mouldable and non-mouldable shapes with voxel sizes as small as 2.0 × 2.0 µm2 in the print plane and 1.1 ± 0.3 µm unsupported thickness, at speeds of up to 1,000,000 particles per day. Such microscopic particles with permutable, intricate designs enable direct integration within biomedical, analytical and advanced materials applications.

Advanced Nanomaterials in Medical 3D Printing

3D printing is now recognized as a significant tool for medical research and clinical practice, leading to the emergence of medical 3D printing technology. It is essential to improve the properties of 3D-printed products to meet the demand for medical use. The core of generating qualified 3D printing products is to develop advanced materials and processes. Taking advantage of nanomaterials with tunable and distinct physical, chemical, and biological properties, integrating nanotechnology into 3D printing creates new opportunities for advancing medical 3D printing field. Recently, some attempts are made to improve medical 3D printing through nanotechnology, providing new insights into developing advanced medical 3D printing technology. With high-resolution 3D printing technology, nano-structures can be directly fabricated for medical applications. Incorporating nanomaterials into the 3D printing material system can improve the properties of the 3D-printed medical products. At the same time, nanomaterials can be used to expand novel medical 3D printing technologies. This review introduced the strategies and progresses of improving medical 3D printing through nanotechnology and discussed challenges in clinical translation.

Three-dimensional nanoscale metal, metal oxide, and semiconductor frameworks through DNA-programmable assembly and templating

Controlling the three-dimensional (3D) nanoarchitecture of inorganic materials is imperative for enabling their novel mechanical, optical, and electronic properties. Here, by exploiting DNA-programmable assembly, we establish a general approach for realizing designed 3D ordered inorganic frameworks. Through inorganic templating of DNA frameworks by liquid- and vapor-phase infiltrations, we demonstrate successful nanofabrication of diverse classes of inorganic frameworks from metal, metal oxide and semiconductor materials, as well as their combinations, including zinc, aluminum, copper, molybdenum, tungsten, indium, tin, and platinum, and composites such as aluminum-doped zinc oxide, indium tin oxide, and platinum/aluminum-doped zinc oxide. The open 3D frameworks have features on the order of nanometers with architecture prescribed by the DNA frames and self-assembled lattice. Structural and spectroscopic studies reveal the composition and organization of diverse inorganic frameworks, as well as the optoelectronic properties of selected materials. The work paves the road toward establishing a 3D nanoscale lithography.

3D-Printed Hydrogel for Diverse Applications: A Review

Hydrogels have emerged as a versatile and promising class of materials in the field of 3D printing, offering unique properties suitable for various applications. This review delves into the intersection of hydrogels and 3D printing, exploring current research, technological advancements, and future directions. It starts with an overview of hydrogel basics, including composition and properties, and details various hydrogel materials used in 3D printing. The review explores diverse 3D printing methods for hydrogels, discussing their advantages and limitations. It emphasizes the integration of 3D-printed hydrogels in biomedical engineering, showcasing its role in tissue engineering, regenerative medicine, and drug delivery. Beyond healthcare, it also examines their applications in the food, cosmetics, and electronics industries. Challenges like resolution limitations and scalability are addressed. The review predicts future trends in material development, printing techniques, and novel applications.

A study of the spectral signal effect of self-holes in metal additive manufacturing components using laser-induced breakdown spectroscopy (LIBS)

Understanding the detection mechanism of hole defects in metal additive manufacturing (AM) components is of great significance for the detection of metal AM component defects using laser-induced breakdown spectroscopy (LIBS). In this work, the mapping relationship between the hole defects of metal AM components and the LIBS spectral signal was studied using the controlled variable method. The effect of hole defects mostly showed a suppression effect and peaked at a hole depth of 1.0 mm when the LIBS system was at its optimal excitation parameter. To explore the possible reasons behind the inhibitory effect of self-holes, the variation law of the plasma temperature with and without hole defects was further investigated. Our results showed that the plasma temperature change curve was similar to the spectral line intensity change trend. Finally, the linear relationship between the focal length effect and the hole effect, and the relationship between the constraint effect and the hole effect were studied. The minimum fitting R2 between the constraint effect and the hole effect was 0.979. We believed that the inhibition of the hole effect was mainly caused by the absorption and loss of energy in the plasma during the process of plasma radiation and shock wave reflection from the hole wall. By studying the detection mechanism of hole defects in metal additive manufacturing components excited by LIBS and finding the effective characteristics of hole defects in metal AM components, it is helpful to achieve higher precision and higher sensitivity defect detection.

Pressure-Activatable Liquid Metal Composites Flexible Sensor with Antifouling and Drag Reduction Functional Surface

Flexible sensors produced through three-dimensional (3D) printing have exhibited promising results in the context of underwater sensing detection (for applications in navigational vehicles and human activities). However, underwater vehicles and activities such as swimming and diving are highly susceptible to drag, which can cause negative impacts such as reduced speed and increased energy consumption. Additionally, microbial adhesion can shorten the service life of these vehicles. However, natural organisms are able to circumvent such problems, with shark skin offering excellent barrier properties and ruffled papillae providing effective protection against fouling. Here, we show that a sandwich system consisting of a spraying layer, conductive elastomer composite, and encapsulation layer can be printed for multifunctional integrated underwater sensors. The modulated viscoelastic properties of liquid metal form the foundation for printing features, while its pressure-activated properties offer the potential for switchable sensors. An integrated drag reduction and antifouling layer were created by combining the shark skin surface shield scale structure with the lotus leaf surface papillae structure. A 3D-printed flexible sensor was designed using our approach to monitor attitude changes and strain in underwater environments, showcasing its capabilities. Our printed sensors can reduce biological attachment density by more than 50% and reduce underwater drag by 8.6-10.3%.

High Freshwater Flux Solar Desalination via a 3D Plasmonic Evaporator with an Efficient Heat-Mass Evaporation Interface

Passive solar desalination with interfacial heating is a promising technique to utilize solar energy to convert seawater into fresh water through evaporation and condensation. However, the current freshwater flux of solar desalination is much below industrial requirements (> 20 L m-2  h-1 ). Herein, it is demonstrated that a 3D plasmonic evaporator with an efficient heat-mass evaporation interface (HM-EI) achieves a freshwater flux of 29.1 L m-2  h-1 for 3.5 wt.% NaCl, which surpasses the previous solar evaporators and approaches the level of reverse osmosis (the highest installed capacity in industrial seawater desalination technology). The realization of high freshwater flux solar desalination comes from the efficient HM-EI comprising a grid-like plasmonic macrostructure for enhanced energy utilization in heat properties and a large-pore microstructure for accelerated ion transport in mass properties. This work provides a new direction for designing next-generation solar evaporators with high freshwater flux for industrial requirements.

Accessibility and Mechanical Stability of Nanoporous Zinc Oxide and Aluminum Oxide Coatings Synthesized via Infiltration of Polymer Templates

The conformal nanoporous inorganic coatings with accessible pores that are stable under applied thermal and mechanical stresses represent an important class of materials used in the design of sensors, optical coatings, and biomedical systems. Here, we synthesize porous AlOx and ZnO coatings by the sequential infiltration synthesis (SIS) of two types of polymers that enable the design of porous conformal coatings-polymers of intrinsic microporosity (PIM) and block co-polymer (BCP) templates. Using quartz crystal microbalance (QCM), we show that alumina precursors infiltrate both polymer templates four times more efficiently than zinc oxide precursors. Using the quartz crystal microbalance (QCM) technique, we provide a comprehensive study on the room temperature accessibility to water and ethanol of pores in block copolymers (BCPs) and porous polymer templates using polystyrene-block-poly-4-vinyl pyridine (PS75-b-P4VP25) and polymers of intrinsic microporosity (PIM-1), polymer templates modified by swelling, and porous inorganic coatings such as AlOx and ZnO synthesized by SIS using such templates. Importantly, we demonstrate that no structural damage occurs in inorganic nanoporous AlOx and ZnO coatings synthesized via infiltration of the polymer templates during the water freezing/melting cycling tests, suggesting excellent mechanical stability of the coatings, even though the hardness of the inorganic nanoporous coating is affected by the polymer and precursor selections. We show that the hardness of the coatings is further improved by their annealing at 900 °C for 1 h, though for all the cases except ZnO obtained using the BCP template, this annealing has a negligible effect on the porosity of the material, as is confirmed by the consistency in the optical characteristics. These findings unravel new potential for the materials being used across various environment and temperature conditions.

Mechanically-Guided 3D Assembly for Architected Flexible Electronics

Architected flexible electronic devices with rationally designed 3D geometries have found essential applications in biology, medicine, therapeutics, sensing/imaging, energy, robotics, and daily healthcare. Mechanically-guided 3D assembly methods, exploiting mechanics principles of materials and structures to transform planar electronic devices fabricated using mature semiconductor techniques into 3D architected ones, are promising routes to such architected flexible electronic devices. Here, we comprehensively review mechanically-guided 3D assembly methods for architected flexible electronics. Mainstream methods of mechanically-guided 3D assembly are classified and discussed on the basis of their fundamental deformation modes (i.e., rolling, folding, curving, and buckling). Diverse 3D interconnects and device forms are then summarized, which correspond to the two key components of an architected flexible electronic device. Afterward, structure-induced functionalities are highlighted to provide guidelines for function-driven structural designs of flexible electronics, followed by a collective summary of their resulting applications. Finally, conclusions and outlooks are given, covering routes to achieve extreme deformations and dimensions, inverse design methods, and encapsulation strategies of architected 3D flexible electronics, as well as perspectives on future applications.

Suppressed Size Effect in Nanopillars with Hierarchical Microstructures Enabled by Nanoscale Additive Manufacturing

Studies on mechanical size effects in nanosized metals unanimously highlight both intrinsic microstructures and extrinsic dimensions for understanding size-dependent properties, commonly focusing on strengths of uniform microstructures, e.g., single-crystalline/nanocrystalline and nanoporous, as a function of pillar diameters, D. We developed a hydrogel infusion-based additive manufacturing (AM) technique using two-photon lithography to produce metals in prescribed 3D-shapes with ∼100 nm feature resolution. We demonstrate hierarchical microstructures of as-AM-fabricated Ni nanopillars (D ∼ 130-330 nm) to be nanoporous and nanocrystalline, with d ∼ 30-50 nm nanograins subtending each ligament in bamboo-like arrangements and pores with critical dimensions comparable to d. In situ nanocompression experiments unveil their yield strengths, σ, to be ∼1-3 GPa, above single-crystalline/nanocrystalline counterparts in the D range, a weak size dependence, σ ∝ D-0.2, and localized-to-homogenized transition in deformation modes mediated by nanoporosity, uncovered by molecular dynamics simulations. This work highlights hierarchical microstructures on mechanical response in nanosized metals and suggests small-scale engineering opportunities through AM-enabled microstructures.

A liquid-free conducting ionoelastomer for 3D printable multifunctional self-healing electronic skin with tactile sensing capabilities

Conductive elastomers with both softness and conductivity are widely used in the field of flexible electronics. Nonetheless, conductive elastomers typically exhibit prominent problems such as solvent volatilization and leakage, and poor mechanical and conductive properties, which limit their applications in electronic skin (e-skin). In this work, a liquid-free conductive ionogel (LFCIg) with excellent performance was fabricated by utilizing the innovative double network design approach based on a deep eutectic solvent (DES). The double-network LFCIg is cross-linked by dynamic non-covalent bonds, which exhibit excellent mechanical properties (2100% strain while sustaining a fracture strength of 1.23 MPa) and >90% self-healing efficiency, and a superb electrical conductivity of 23.3 mS m-1 and 3D printability. Moreover, the conductive elastomer based on LFCIg has been developed into a stretchable strain sensor that achieves accurate response recognition, classification, and identification of different robot gestures. More impressively, an e-skin with tactile sensing functions is produced by in situ 3D printing of sensor arrays on flexible electrodes to detect light weight objects and recognize the resulting spatial pressure variations. Collectively, the results demonstrate that the designed LFCIg has unparalleled advantages and presents wide application potential in flexible robotics, e-skin and physiological signal monitoring.

Metal 3D nanoprinting with coupled fields

Metallized arrays of three-dimensional (3D) nanoarchitectures offer new and exciting prospects in nanophotonics and nanoelectronics. Engineering these repeating nanoarchitectures, which have dimensions smaller than the wavelength of the light source, enables in-depth investigation of unprecedented light-matter interactions. Conventional metal nanomanufacturing relies largely on lithographic methods that are limited regarding the choice of materials and machine write time and are restricted to flat patterns and rigid structures. Herein, we present a 3D nanoprinter devised to fabricate flexible arrays of 3D metallic nanoarchitectures over areas up to 4 × 4 mm2 within 20 min. By suitably adjusting the electric and flow fields, metal lines as narrow as 14 nm were printed. We also demonstrate the key ability to print a wide variety of materials ranging from single metals, alloys to multimaterials. In addition, the optical properties of the as-printed 3D nanoarchitectures can be tailored by varying the material, geometry, feature size, and periodic arrangement. The custom-designed and custom-built 3D nanoprinter not only combines metal 3D printing with nanoscale precision but also decouples the materials from the printing process, thereby yielding opportunities to advance future nanophotonics and semiconductor devices.

Diffusion-Limited Processes in Hydrogels with Chosen Applications from Drug Delivery to Electronic Components

Diffusion is one of the key nature processes which plays an important role in respiration, digestion, and nutrient transport in cells. In this regard, the present article aims to review various diffusion approaches used to fabricate different functional materials based on hydrogels, unique examples of materials that control diffusion. They have found applications in fields such as drug encapsulation and delivery, nutrient delivery in agriculture, developing materials for regenerative medicine, and creating stimuli-responsive materials in soft robotics and microrobotics. In addition, mechanisms of release and drug diffusion kinetics as key tools for material design are discussed.

A Generalized Polymer Precursor Ink Design for 3D Printing of Functional Metal Oxides

Three-dimensional-structured metal oxides have myriad applications for optoelectronic devices. Comparing to conventional lithography-based manufacturing methods which face significant challenges for 3D device architectures, additive manufacturing approaches such as direct ink writing offer convenient, on-demand manufacturing of 3D oxides with high resolutions down to sub-micrometer scales. However, the lack of a universal ink design strategy greatly limits the choices of printable oxides. Here, a universal, facile synthetic strategy is developed for direct ink writable polymer precursor inks based on metal-polymer coordination effect. Specifically, polyethyleneimine functionalized by ethylenediaminetetraacetic acid is employed as the polymer matrix for adsorbing targeted metal ions. Next, glucose is introduced as a crosslinker for endowing the polymer precursor inks with a thermosetting property required for 3D printing via the Maillard reaction. For demonstrations, binary (i.e., ZnO, CuO, In2O3, Ga2O3, TiO2, and Y2O3) and ternary metal oxides (i.e., BaTiO3 and SrTiO3) are printed into 3D architectures with sub-micrometer resolution by extruding the inks through ultrafine nozzles. Upon thermal crosslinking and pyrolysis, the 3D microarchitectures with woodpile geometries exhibit strong light-matter coupling in the mid-infrared region. The design strategy for printable inks opens a new pathway toward 3D-printed optoelectronic devices based on functional oxides.