3D Printed Graphene Based Energy Storage Devices

Exploring the potential of 3D-printed solvent activated electrodes for salicylic acid analysis

This study evaluates the electrochemical properties of tetrahydrofuran (THF)-activated 3D-printed polylactic acid-carbon black (PLA-CB) electrodes. The electrodes were characterized using SEM, ATR-FTIR, contact angle measurements, and optical profilometry to assess the effects of THF activation on their surface and chemical properties. A range of redox probes were used to investigate both, outer- and inner-sphere electron transfer processes, providing a comprehensive understanding of the electrode's electrochemical behavior. The activated electrodes were further tested for their ability to determine salicylic acid (SA) using differential pulse voltammetry (DPV). Calibration curves were constructed, and preliminary analyses of SA in cosmetic products, including a face serum and a cream, were performed. Obtained data are critically assessed.

Advances and future perspectives on silicon-based anodes for lithium-ion batteries

Silicon (Si)-based anode has emerged as the most promising anode material for next-generation lithium-ion batteries (LIBs) due to its high specific capacity, suitable operating potential and abundant natural reserves. Nevertheless, the drastic volume effect of Si particles during lithiation/delithiation leads to particle pulverization, electrode structure collapse, and solid electrolyte interfacial (SEI) film instability, which results in a rapid reversible capacity degradation of Si-based anodes. It is essential to deeply analyze the failure mechanism of silicon-based electrodes and explore suitable improvement methods to achieve higher capacity retention. Herein, we systematically summarize the improvement strategies for Si-based anodes, including regulating material particle size, optimizing structure and composition, and exploring new binders, along with their enhancement mechanisms. In addition, the preparation of high-performance Si-based electrodes based on newly developed 3D printing technology in recent years is discussed. Lastly, several possible directions and emerging challenges for Si anode are presented to facilitate further improvement in practical applications. Overall, this review is expected to provide basic understanding and insights into the practical application of Si-based materials in next-generation LIBs negative electrodes.

Reversible Thixotropic Rheological Properties of Graphene-Incorporated Epoxy Inks for Self-Standing 3D Printing

As three-dimensional (3D) printing has emerged as a new manufacturing technology, the demand for high-performance 3D printable materials has increased to ensure broad applicability in various load-bearing structures. In particular, the thixotropic properties of materials, which allow them to flow under applied external forces but resist flowing otherwise, have been reported to enable rapid and high-resolution printing owing to their self-standing and easily processable characteristics. In this context, graphene nanosheets exhibit unique π-π stacking interactions between neighboring sheets, likely imparting self-standing capability to low-viscosity inks. Herein, we develop a thermally curable graphene-incorporated epoxy ink system that exhibits shear-thinning characteristics and upright standing capability owing to its high static yield stress (∼1,680 Pa). The reversible liquid-to-solid phase transition of the composite ink, absent in the pristine epoxy ink, is clearly identified by its viscoelastic properties and dynamic yield stress. This thixotropic composite ink enables the continuous filament printing of 10 stacked layers without the spreading of injected filaments. Significantly, the 3D-printed composite structure, post-thermal curing, exhibits robust structural integrity and is free from weld lines or voids at the stacked interfaces. Combined with the clearly elucidated processing-structure-property relationships of the ink system, our results highlight its potential for a wide spectrum of applications.

Advances in 4D Bioprinting: The Next Frontier in Regenerative Medicine and Tissue Engineering Applications

4D bioprinting is a critical advancement in tissue engineering and regenerative medicine (TERM), enabling the creation of structures that dynamically respond to environmental stimuli over time. This review investigates various fabrication techniques and responsive materials that are central to these fields. It underscores the integration of multi-material and biocomposite approaches in 4D bioprinting, which is crucial for fabricating complex and functional constructs with heterogeneous properties. Using 4D bioprinting techniques enhances the mimicry of natural tissue characteristics, offering tailored responses and improved integration with biological systems. Furthermore, this study highlights the synergy between 4D bioprinting and tissue engineering and demonstrates the technology's potential for developing tissues and organs. In regenerative medicine, 4D bioprinting's applications extend to creating smart implants and advanced drug delivery systems that adapt to the body's changes, promoting healing and tissue regeneration. Finally, the challenges and future directions of 4D bioprinting are also explored and emphasize its transformative impact on biomedical engineering and the future of healthcare.

3D-Printed Lithium-Ion Battery Electrodes: A Brief Review of Three Key Fabrication Techniques

In recent years, 3D printing has emerged as a promising technology in energy storage, particularly for the fabrication of Li-ion battery electrodes. This innovative manufacturing method offers significant material composition and electrode structure flexibility, enabling more complex and efficient designs. While traditional Li-ion battery fabrication methods are well-established, 3D printing opens up new possibilities for enhancing battery performance by allowing for tailored geometries, efficient material usage, and integrating multifunctional components. This article examines three key 3D printing methods for fabricating Li-ion battery electrodes: (1) material extrusion (ME), which encompasses two subcategories-fused deposition modeling (FDM), also referred to as fused filament fabrication (FFF), and direct ink writing (DIW); (2) material jetting (MJ), including inkjet printing (IJP) and aerosol jet printing (AJP) methods; and (3) vat photopolymerization (VAT-P), which includes the stereolithographic apparatus (SLA) subcategory. These methods have been applied in fabricating substrates, thin-film electrodes, and electrolytes for half-cell and full-cell Li-ion batteries. This discussion focuses on their strengths, limitations, and potential advancements for energy storage applications.

Utilizing Binary Phase Segregation and Extrusion to Enhance the Electronic Properties of Graphene Nanocomposites

Our goal in this study is to incorporate graphene nanoplatelets (GNPs) in a polymer blend of poly(lactic acid) (PLA) and isotactic polypropylene (iPP) to facilitate the dispersion of GNPs and use the morphology of phase segregation to create a pathway for concentrating GNPs to achieve percolation with lower GNP concentration. Investigating the interfacial properties between PLA/GNPs and iPP/GNPs, we noticed that iPP has a lower contact angle on GNPs compared to PLA on GNPs. This showed a great potential that the GNP are easily confined in iPP rather than in PLA domains or at the PLA/PP interfaces. Utilizing this property, as the PLA content increases, the iPP content decreases, resulting in a reduction of the available space for GNPs. This decrease in space leads to a higher chance for GNPs to accumulate together. Furthermore, through careful control of the concentration in the immiscible blend of PLA/PP, it is possible to achieve a bicontinuous structure. This structure facilitates the creation of a pathway for the fillers, allowing for the use of minimal GNPs while achieving optimal electrical conductivity properties. The PLA/PP/GNPs can be oriented by the shear forces coming from the nozzle that produce a higher performance.

Innovative Hybrid Nanocomposites in 3D Printing for Functional Applications: A Review

3D printing has garnered significant attention across academia and industry due to its capability to design and fabricate complex architectures. Applications such as those requiring intricate geometries or custom designs, including footwear, healthcare, energy storage, and electronics applications, greatly benefit from exploiting 3D printing processes. Despite the recent advancement of structural 3D printing, its use in functional devices remains limited, requiring the need for the development of functional materials suitable for 3D printing in device fabrication. In this review, we briefly introduce various 3D printing techniques, including material extrusion and vat polymerization, and highlight the recent advances in 3D printing for energy and biomedical devices. A summary of future perspectives in this area is also presented. By highlighting recent developments and addressing key challenges, this review aims to inspire future directions in the development of functional devices.

3D printed microfluidic devices with electrodes for electrochemical analysis

A review with 93 references describing various 3D printing approaches that have been used to create microfluidic devices containing electrodes for electrochemical detection. The use of 3D printing to fabricate microfluidic devices is a rapidly growing area. One significant research area is how to detect analytes in the devices for quantitation purposes. This review article is focused on methods used to integrate electrodes into the devices for electrochemical detection. The review is organized in terms of the methodology for integrating the electrode within the device. This includes (1) external coupling of traditional electrode materials with 3D printed devices; (2) printing conductive electrode materials as part of device printing; and (3) integrating traditional electrodes into the device as part of the print process. Example applications are given and some future directions are also outlined.

Conductive Polypropylene Additive Manufacturing Feedstock: Application to Aqueous Electroanalysis and Unlocking Nonaqueous Electrochemistry and Electrosynthesis

Additive manufacturing electrochemistry is an ever-expanding field; however, it is limited to aqueous environments due to the conductive filaments currently available. Herein, the production of a conductive poly(propylene) filament, which unlocks the door to organic electrochemistry and electrosynthesis, is reported. A filament with 40 wt % carbon black possessed enhanced thermal stability, excellent low-temperature flexibility, and high conductivity. The filament produced highly reproducible additive manufactured electrodes that were electrochemically characterized, showing a k0 of 2.00 ± 0.04 × 10-3 cm s-1. This material was then applied to three separate electrochemical applications. First, the electroanalytical sensing of colchicine within environmental waters, where a limit of detection of 10 nM was achieved before being applied to tap, bottled, and river water. Second, the electrodes were stable in organic solvents for 100 cyclic voltammograms and 15 days. Finally, these were applied toward an electrosynthetic reaction of chlorpromazine, where the electrodes were stable for 24-h experiments, outperforming a glassy carbon electrode, and were able to be reused while maintaining a good electrochemical performance. This material can revolutionize the field of additive manufacturing electrochemistry and expand research into a variety of new fields.

Evaluating the Piezoelectric Energy Harvesting Potential of 3D-Printed Graphene Prepared Using Direct Ink Writing and Fused Deposition Modelling

This research aims to use energy harvested from conductive materials to power microelectronic components. The proposed method involves using vibration-based energy harvesting to increase the natural vibration frequency, reduce the need for battery replacement, and minimise chemical waste. Piezoelectric transduction, known for its high-power density and ease of application, has garnered significant attention. Additionally, graphene, a non-piezoelectric material, exhibits good piezoelectric properties. The research explores a novel method of printing graphene material using 3D printing, specifically Direct Ink Writing (DIW) and fused deposition modelling (FDM). Both simulation and experimental techniques were used to analyse energy harvesting. The experimental technique involved using the cantilever beam-based vibration energy harvesting method. The results showed that the DIW-derived 3D-printed prototype achieved a peak power output of 12.2 µW, surpassing the 6.4 µW output of the FDM-derived 3D-printed prototype. Furthermore, the simulation using COMSOL Multiphysics yielded a harvested output of 0.69 µV.

Ultrafast Laser Processing of 2D Materials: Novel Routes to Advanced Devices

Ultrafast laser processing has emerged as a versatile technique for modifying materials and introducing novel functionalities. Over the past decade, this method has demonstrated remarkable advantages in the manipulation of 2D layered materials, including synthesis, structuring, functionalization, and local patterning. Unlike continuous-wave and long-pulsed optical methods, ultrafast lasers offer a solution for thermal heating issues. Nonlinear interactions between ultrafast laser pulses and the atomic lattice of 2D materials substantially influence their chemical and physical properties. This paper highlights the transformative role of ultrafast laser pulses in maskless green technology, enabling subtractive, and additive processes that unveil ways for advanced devices. Utilizing the synergetic effect between the energy states within the atomic layers and ultrafast laser irradiation, it is feasible to achieve unprecedented resolutions down to several nanometers. Recent advancements are discussed in functionalization, doping, atomic reconstruction, phase transformation, and 2D and 3D micro- and nanopatterning. A forward-looking perspective on a wide array of applications of 2D materials, along with device fabrication featuring novel physical and chemical properties through direct ultrafast laser writing, is also provided.

Recycled PETg embedded with graphene, multi-walled carbon nanotubes and carbon black for high-performance conductive additive manufacturing feedstock

The first report of conductive recycled polyethylene terephthalate glycol (rPETg) for additive manufacturing and electrochemical applications is reported herein. Graphene nanoplatelets (GNP), multi-walled carbon nanotubes (MWCNT) and carbon black (CB) were embedded within a recycled feedstock to produce a filament with lower resistance than commercially available conductive polylactic acid (PLA). In addition to electrical conductivity, the rPETg was able to hold >10 wt% more conductive filler without the use of a plasticiser, showed enhanced temperature stability, had a higher modulus, improved chemical resistance, lowered levels of solution ingress, and could be sterilised in ethanol. Using a mix of carbon materials CB/MWCNT/GNP (25/2.5/2.5 wt%) the electrochemical performance of the rPETg filament was significantly enhanced, providing a heterogenous electrochemical rate constant, k0, equating to 0.88 (±0.01) × 10-3 cm s-1 compared to 0.46 (±0.02) × 10-3 cm s-1 for commercial conductive PLA. This work presents a paradigm shift within the use of additive manufacturing and electrochemistry, allowing the production of electrodes with enhanced electrical, chemical and mechanical properties, whilst improving the sustainability of the production through the use of recycled feedstock.

Current significance and future perspective of 3D-printed bio-based polymers for applications in energy conversion and storage system

The increasing global population has led to a surge in energy demand and the production of environmentally harmful products, highlighting the urgent need for renewable and clean energy sources. In this context, sustainable and eco-friendly energy production strategies have been explored to mitigate the adverse effects of fossil fuel consumption to the environment. Additionally, efficient energy storage devices with a long lifespan are also crucial. Tailoring the components of energy conversion and storage devices can improve overall performance. Three-dimensional (3D) printing provides the flexibility to create and optimize geometrical structure in order to obtain preferable features to elevate energy conversion yield and storage capacitance. It also serves the potential for rapid and cost-efficient manufacturing. Besides that, bio-based polymers with potential mechanical and rheological properties have been exploited as material feedstocks for 3D printing. The use of these polymers promoted carbon neutrality and environmentally benign processes. In this perspective, this review provides an overview of various 3D printing techniques and processing parameters for bio-based polymers applicable for energy-relevant applications. It also explores the advances and current significance on the integration of 3D-printed bio-based polymers in several energy conversion and storage components from the recently published studies. Finally, the future perspective is elaborated for the development of bio-based polymers via 3D printing techniques as powerful tools for clean energy supplies towards the sustainable development goals (SDGs) with respect to environmental protection and green energy conversion.

Current perspectives, challenges, and future directions in the electrochemical detection of microplastics

Microplastics (5 μm) are a developing threat that contaminate every environmental compartment. The detection of these contaminants is undoubtedly an important topic of study because of their high potential to cause harm to ecosystems. For many years, scientists have been assiduously striving to surmount the obstacle of detection restrictions and minimize the likelihood of receiving results that are either false positives or false negatives. This study covers the current state of electrochemical sensing technology as well as its application as a low-cost analytical platform for the detection and characterization of novel contaminants. Examples of detection mechanisms, electrode modification procedures, device configuration, and performance are given to show how successful these approaches are for monitoring microplastics in the environment. Additionally included are the recent developments in nanoimpact techniques. Compared to electrochemical methods for microplastic remediation, the use of electrochemical sensors for microplastic detection has received very little attention. With an overview of microplastic electrochemical sensors, this review emphasizes the promise of existing electrochemical remediation platforms toward sensor design and development. In order to enhance the monitoring of these substances, a critical assessment of the requirements for future research, challenges associated with detection, and opportunities is provided. In addition to-or instead of-the now-in-use laboratory-based analytical equipment, these technologies can be utilized to support extensive research and manage issues pertaining to microplastics in the environment and other matrices.

Realizing Highly-Ordered Laser-Reduced Graphene for High-Performance Flexible Microsupercapacitor

Laser reduction of graphene oxide (GO) with direct-write technology is promising to develop miniaturized energy storage devices because of highly flexible, mask-free, and chemical-free merits. However, laser reduction of GO is often accompanied with deflagration (spectacular and violent deoxygenating reaction), leading reduced graphene oxide (rGO) films into brittle and irregular internal structure which is harmful to the applications. Here, a pre-reduction strategy is demonstrated to avoid this deflagration and realize a uniform laser-reduced GO (LrGO) matrix for the application of flexible micro-supercapacitors (MSCs).The pre-reduction process with ascorbic acid decreases the content of oxygen-containing functional groups on GO in advance, and thus relieves gases emission and avoids unconstrained expansion during the laser reduction process. In addition, a self-assembled skeleton with pre-reduced GO (PGO) nanosheets could be constructed which is a more appropriate aforehand framework for laser reduction to establish controllable rGO films with the homogenous porosity. The quasi-solid-state MSCs assembled with laser-reduced PGO exhibit the maximum areal capacitance of 88.32 mF cm-2 , good cycling performance (capacitance retention of 82% after 2000 cycles), and outstanding flexibility (no capacitance degradation after bending for 5000 times). This finding provides opportunities to enhance quality of LrGO which is promising for micro-power devices and beyond.

3D Printing-Enabled Design and Manufacturing Strategies for Batteries: A Review

Lithium-ion batteries (LIBs) have significantly impacted the daily lives, finding broad applications in various industries such as consumer electronics, electric vehicles, medical devices, aerospace, and power tools. However, they still face issues (i.e., safety due to dendrite propagation, manufacturing cost, random porosities, and basic & planar geometries) that hinder their widespread applications as the demand for LIBs rapidly increases in all sectors due to their high energy and power density values compared to other batteries. Additive manufacturing (AM) is a promising technique for creating precise and programmable structures in energy storage devices. This review first summarizes light, filament, powder, and jetting-based 3D printing methods with the status on current trends and limitations for each AM technology. The paper also delves into 3D printing-enabled electrodes (both anodes and cathodes) and solid-state electrolytes for LIBs, emphasizing the current state-of-the-art materials, manufacturing methods, and properties/performance. Additionally, the current challenges in the AM for electrochemical energy storage (EES) applications, including limited materials, low processing precision, codesign/comanufacturing concepts for complete battery printing, machine learning (ML)/artificial intelligence (AI) for processing optimization and data analysis, environmental risks, and the potential of 4D printing in advanced battery applications, are also presented.

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

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

3D printed electronics with nanomaterials

A large variety of printing, deposition and writing techniques have been incorporated to fabricate electronic devices in the last decades. This approach, printed electronics, has gained great interest in research and practical applications and is successfully fuelling the growth in materials science and technology. On the other hand, a new player is emerging, additive manufacturing, called 3D printing, introducing a new capability to create geometrically complex constructs with low cost and minimal material waste. Having such tremendous technology in our hands, it was just a matter of time to combine advances of printed electronics technology for the fabrication of unique 3D structural electronics. Nanomaterial patterning with additive manufacturing techniques can enable harnessing their nanoscale properties and the fabrication of active structures with unique electrical, mechanical, optical, thermal, magnetic and biological properties. In this paper, we will briefly review the properties of selected nanomaterials suitable for electronic applications and look closer at the current achievements in the synergistic integration of nanomaterials with additive manufacturing technologies to fabricate 3D printed structural electronics. The focus is fixed strictly on techniques allowing as much as possible fabrication of spatial 3D objects, or at least conformal ones on 3D printed substrates, while only selected techniques are adaptable for 3D printing of electronics. Advances in the fabrication of conductive paths and circuits, passive components, antennas, active and photonic components, energy devices, microelectromechanical systems and sensors are presented. Finally, perspectives for development with new nanomaterials, multimaterial and hybrid techniques, bioelectronics, integration with discrete components and 4D-printing are briefly discussed.

Circular Economy Electrochemistry: Creating Additive Manufacturing Feedstocks for Caffeine Detection from Post-Industrial Coffee Pod Waste

The recycling of post-industrial waste poly(lactic acid) (PI-PLA) from coffee machine pods into electroanalytical sensors for the detection of caffeine in real tea and coffee samples is reported herein. The PI-PLA is transformed into both nonconductive and conductive filaments to produce full electroanalytical cells, including additively manufactured electrodes (AMEs). The electroanalytical cell was designed utilizing separate prints for the cell body and electrodes to increase the recyclability of the system. The cell body made from nonconductive filament was able to be recycled three times before the feedstock-induced print failure. Three bespoke formulations of conductive filament were produced, with the PI-PLA (61.62 wt %), carbon black (CB, 29.60 wt %), and poly(ethylene succinate) (PES, 8.78 wt %) chosen as the most suitable for use due to its equivalent electrochemical performance, lower material cost, and improved thermal stability compared to the filaments with higher PES loading and ability to be printable. It was shown that this system could detect caffeine with a sensitivity of 0.055 ± 0.001 μA μM^-1, a limit of detection of 0.23 μM, a limit of quantification of 0.76 μM, and a relative standard deviation of 3.14% after activation. Interestingly, the nonactivated 8.78% PES electrodes produced significantly better results in this regard than the activated commercial filament toward the detection of caffeine. The activated 8.78% PES electrode was shown to be able to detect the caffeine content in real and spiked Earl Grey tea and Arabica coffee samples with excellent recoveries (96.7-102%). This work reports a paradigm shift in the way AM, electrochemical research, and sustainability can synergize and feed into part of a circular economy, akin to a circular economy electrochemistry.

Hydrogen Evolution Reaction Performance of Ni-Co-Coated Graphene-Based 3D Printed Electrodes

Additive manufacturing has been a very promising topic in recent years for research and development studies and industrial applications. Its electrochemical applications are very popular due to the cost-effective rapid production from the environmentally friendly method. In this study, three-dimensional (3D) printed electrodes are prepared by Ni and Co coatings in different molar ratios. Different Ni/Co molar ratios (x:y) of the Ni/Co/x:y alloys are prepared as 1:1, 1:4, and 4:1 and they are named Ni/Co/1:1, Ni/Co/4:1, and Ni/Co/1:4, respectively. According to the results, when the 3D electrode samples are coated with Ni and Co at different molar ratios, the kinetic performance of the NiCo-coated 3D electrode samples for hydrogen evolution reaction is enhanced compared to that of the uncoated 3D electrode sample. The results indicate that the Ni/Co/1:4-coated 3D electrode has the highest kinetic activity for hydrogen evolution reactions (HERs). The calculated Tafel's slope and overpotential value (η₁₀) for HER are determined as 164.65 mV/dec and 101.92 mV, respectively. Moreover, the Ni/Co/1:4-coated 3D electrode has an 81.2% higher current density than the other electrode. It is observed that the 3D printing of the electrochemical electrodes is very promising when they are coated with Ni-Co metals in different ratios. This study provides a new perspective on the use of 3D printed electrodes for high-performance water electrolysis.

Self-Monitoring Performance of 3D-Printed Poly-Ether-Ether-Ketone Carbon Nanotube Composites

In this paper, poly-ether-ether-ketone (PEEK) carbon-nanotube (CNT) self-monitoring composites at different levels of filler loading (i.e., 3, 5 and 10% by weight) have been extruded as 3D-printable filaments, showing gauge factor values of 14.5, 3.36 and 1.99, respectively. CNT composite filaments of 3 and 5 wt% were 3D-printed into tensile samples, while the PEEK 10CNT filament was found to be barely printable. The 3D-printed PEEK 3CNT and PEEK 5CNT composites presented piezo-resistive behavior, with an increase in electrical resistance under mechanical stress, and showed an average gauge factor of 4.46 and 2.03, respectively. Mechanical tests highlighted that 3D-printed samples have a laminate-like behavior, presenting ultimate tensile strength that is always higher than 60 MPa, hence they offer the possibility to detect damages in an orthogonal direction to the applied load wit high sensitivity.

Structured Electrode Additive Manufacturing for Lithium-Ion Batteries

As the world increasingly swaps fossil fuels, significant advances in lithium-ion batteries have occurred over the past decade. Though demand for increased energy density with mechanical stability continues to be strong, attempts to use traditional ink-casting to increase electrode thickness or geometric complexity have had limited success. Here, we combined a nanomaterial orientation with 3D printing and developed a dry electrode processing route, structured electrode additive manufacturing (SEAM), to rapidly fabricate thick electrodes with an out-of-plane aligned architecture with low tortuosity and mechanical robustness. SEAM uses a shear flow of molten feedstock to control the orientation of the anisotropic materials across nano to macro scales, favoring Li-ion transport and insertion. These structured electrodes with 1 mm thickness have more than twice the specific capacity at 1 C compared to slurry-cast electrodes and have higher mechanical properties (compressive strength of 0.84 MPa and modulus of 5 MPa) than other reported 3D-printed electrodes.

Adjusting the Connection Length of Additively Manufactured Electrodes Changes the Electrochemical and Electroanalytical Performance

Changing the connection length of an additively manufactured electrode (AME) has a significant impact on the electrochemical and electroanalytical response of the system. In the literature, many electrochemical platforms have been produced using additive manufacturing with great variations in how the AME itself is described. It is seen that when measuring the near-ideal outer-sphere redox probe hexaamineruthenium (III) chloride (RuHex), decreasing the AME connection length enhances the heterogeneous electrochemical transfer (HET) rate constant (k0) for the system. At slow scan rates, there is a clear change in the peak-to-peak separation (ΔEp) observed in the RuHex voltammograms, with the ΔEp shifting from 118 ± 5 mV to 291 ± 27 mV for the 10 and 100 mm electrodes, respectively. For the electroanalytical determination of dopamine, no significant difference is noticed at low concentrations between 10- and 100-mm connection length AMEs. However, at concentrations of 1 mM dopamine, the peak oxidation is shifted to significantly higher potentials as the AME connection length is increased, with a shift of 150 mV measured. It is recommended that in future work, all AME dimensions, not just the working electrode head size, is reported along with the resistance measured through electrochemical impedance spectroscopy to allow for appropriate comparisons with other reports in the literature. To produce the best additively manufactured electrochemical systems in the future, researchers should endeavor to use the shortest AME connection lengths that are viable for their designs.

An Overview of Various Additive Manufacturing Technologies and Materials for Electrochemical Energy Conversion Applications

Additive manufacturing (AM) technologies have many advantages, such as design flexibility, minimal waste, manufacturing of very complex structures, cheaper production, and rapid prototyping. This technology is widely used in many fields, including health, energy, art, design, aircraft, and automotive sectors. In the manufacturing process of 3D printed products, it is possible to produce different objects with distinctive filament and powder materials using various production technologies. AM covers several 3D printing techniques such as fused deposition modeling (FDM), inkjet printing, selective laser melting (SLM), and stereolithography (SLA). The present review provides an extensive overview of the recent progress in 3D printing methods for electrochemical fields. A detailed review of polymeric and metallic 3D printing materials and their corresponding printing methods for electrodes is also presented. Finally, this paper comprehensively discusses the main benefits and the drawbacks of electrode production from AM methods for energy conversion systems.

Recent advancements in the field of flexible/wearable enzyme fuel cells

This review article focusses on new advances in the field of enzyme fuel cells (EFCs), especially, on flexible materials which can be used to make flexible EFCs for wearable devices, three-dimensional (3D) printed structures to prepare electrodes for EFCs and micro/nano electromechanical structures (MEMS/NEMS) to fabricate micro-EFCs. Particular attention is given to newly developed approaches to obtain efficient electrodes for harvesting energy via EFCs. This review article explains the various attributes of these recently developing technologies and their ability to mitigate the energy requirements of flexible/wearable bioelectronic devices. Besides discussing key milestones achieved, this perspective review article also emphasizes the main hurdles that are currently impeding the realization of flexible/wearable EFCs. We have also emphasized on the major hurdles related to the flexible materials required to fabricate wearable EFCs, suitable 3D printing techniques required, and MEMS and NEMS to fabricate micro-EFCs. In all the recently developed techniques, there are some common issues like stability, low power output, mechanical strength and flexibility. This review article also provides various routes to mitigate these issues. The main aim of this perspective article is to develop curiosity among the researchers of various fields to team up in order to address the huge challenges that restrict the real-world application of flexible/wearable EFCs. Such collaboration is important to harness the full potential of EFCs. It is requested to read this review article with supporting information to get the complete essence.

New carbon black-based conductive filaments for the additive manufacture of improved electrochemical sensors by fused deposition modeling

The development of a homemade carbon black composite filament with polylactic acid (CB-PLA) is reported. Optimized filaments containing 28.5% wt. of carbon black were obtained and employed in the 3D printing of improved electrochemical sensors by fused deposition modeling (FDM) technique. The fabricated filaments were used to construct a simple electrochemical system, which was explored for detecting catechol and hydroquinone in water samples and detecting hydrogen peroxide in milk. The determination of catechol and hydroquinone was successfully performed by differential pulse voltammetry, presenting LOD values of 0.02 and 0.22 µmol L-1, respectively, and recovery values ranging from 91.1 to 112% in tap water. Furthermore, the modification of CB-PLA electrodes with Prussian blue allowed the non-enzymatic amperometric detection of hydrogen peroxide at 0.0 V (vs. carbon black reference electrode) in milk samples, with a linear range between 5.0 and 350.0 mol L-1 and low limit of detection (1.03 µmol L-1). Thus, CB-PLA can be successfully applied as additively manufactured electrochemical sensors, and the easy filament manufacturing process allows for its exploration in a diversity of applications.

Electrochemical Biosensor for SARS-CoV-2 cDNA Detection Using AuPs-Modified 3D-Printed Graphene Electrodes

A low-cost and disposable graphene polylactic (G-PLA) 3D-printed electrode modified with gold particles (AuPs) was explored to detect the cDNA of SARS-CoV-2 and creatinine, a potential biomarker for COVID-19. For that, a simple, non-enzymatic electrochemical sensor, based on a Au-modified G-PLA platform was applied. The AuPs deposited on the electrode were involved in a complexation reaction with creatinine, resulting in a decrease in the analytical response, and thus providing a fast and simple electroanalytical device. Physicochemical characterizations were performed by SEM, EIS, FTIR, and cyclic voltammetry. Square wave voltammetry was employed for the creatinine detection, and the sensor presented a linear response with a detection limit of 0.016 mmol L-1. Finally, a biosensor for the detection of SARS-CoV-2 was developed based on the immobilization of a capture sequence of the viral cDNA upon the Au-modified 3D-printed electrode. The concentration, immobilization time, and hybridization time were evaluated in presence of the DNA target, resulting in a biosensor with rapid and low-cost analysis, capable of sensing the cDNA of the virus with a good limit of detection (0.30 µmol L-1), and high sensitivity (0.583 µA µmol-1 L). Reproducible results were obtained (RSD = 1.14%, n = 3), attesting to the potentiality of 3D-printed platforms for the production of biosensors.

Development and Up-Scaling of Electrochemical Production and Mild Thermal Reduction of Graphene Oxide

To reduce the global emissions of CO2, the aviation industry largely relies on new light weight materials, which require multifunctional coatings. Graphene and its derivatives are particularly promising for combining light weight applications with functional coatings. Although they have proven to have outstanding properties, graphene and its precursor graphene oxide (GO) remain far from application at the industrial scale since a comprehensive protocol for mass production is still lacking. In this work, we develop and systematically describe a sustainable up-scaling process for the production of GO based on a three-step electrochemical exfoliation method. Surface characterization techniques (XRD, XPS and Raman) allow the understanding of the fast exfoliation rates obtained, and of high conductivities that are up to four orders of magnitude higher compared to GO produced via the commonly used modified Hummers method. Furthermore, we show that a newly developed mild thermal reduction at 250 °C is sufficient to increase conductivity by another order of magnitude, while limiting energy requirements. The proposed GO powder protocol suggests an up-scaling linear relation between the amount of educt surface and volume of electrolyte. This may support the mass production of GO-based coatings for the aviation industry, and address challenges such as low weight, fire, de-icing and lightning strike protection.

Three-Dimensional Printed MoS2/Graphene Aerogel Electrodes for Hydrogen Evolution Reactions

In this work, we demonstrate the use of direct ink writing (DIW) technology to create 3D catalytic electrodes for electrochemical applications. Hybrid MoS₂/graphene aerogels are made by mixing commercially available MoS₂ and graphene oxide powders into a thixotropic, high concentration, viscous ink. A porous 3D structure of 2D graphene sheets and MoS₂ particles was created after post treatment by freeze-drying and reducing graphene oxide through annealing. The composition and morphology of the samples were fully characterized through XPS, BET, and SEM/EDS. The resulting 3D printed MoS₂/graphene aerogel electrodes had a remarkable electrochemically active surface area (>1700 cm²) and were able to achieve currents over 100 mA in acidic media. Notably, the catalytic activity of the MoS₂/graphene aerogel electrodes was maintained with minimal loss in surface area compared to the non-3D printed electrodes, suggesting that DIW can be a viable method of producing durable electrodes with a high surface area for water splitting. This demonstrates that 3D printing a MoS₂/graphene 3D porous network directly using our approach not only improves electrolyte dispersion and facilitates catalyst utilization but also provides multidimensional electron transport channels for improving electronic conductivity.

Electrochemical (Bio)Sensors Enabled by Fused Deposition Modeling-Based 3D Printing: A Guide to Selecting Designs, Printing Parameters, and Post-Treatment Protocols

The 3D printing (or additive manufacturing, AM) technology is capable to provide a quick and easy production of objects with freedom of design, reducing waste generation. Among the AM techniques, fused deposition modeling (FDM) has been highlighted due to its affordability, scalability, and possibility of processing an extensive range of materials (thermoplastics, composites, biobased materials, etc.). The possibility of obtaining electrochemical cells, arrays, pieces, and more recently, electrodes, exactly according to the demand, in varied shapes and sizes, and employing the desired materials has made from 3D printing technology an indispensable tool in electroanalysis. In this regard, the obtention of an FDM 3D printer has great advantages for electroanalytical laboratories, and its use is relatively simple. Some care has to be taken to aid the user to take advantage of the great potential of this technology, avoiding problems such as solution leakages, very common in 3D printed cells, providing well-sealed objects, with high quality. In this sense, herein, we present a complete protocol regarding the use of FDM 3D printers for the fabrication of complete electrochemical systems, including (bio)sensors, and how to improve the quality of the obtained systems. A guide from the initial printing stages, regarding the design and structure obtention, to the final application, including the improvement of obtained 3D printed electrodes for different purposes, is provided here. Thus, this protocol can provide great perspectives and alternatives for 3D printing in electroanalysis and aid the user to understand and solve several problems with the use of this technology in this field.

New conductive filament ready-to-use for 3D-printing electrochemical (bio)sensors: Towards the detection of SARS-CoV-2

The 3D printing technology has gained ground due to its wide range of applicability. The development of new conductive filaments contributes significantly to the production of improved electrochemical devices. In this context, we report a simple method to producing an efficient conductive filament, containing graphite within the polymer matrix of PLA, and applied in conjunction with 3D printing technology to generate (bio)sensors without the need for surface activation. The proposed method for producing the conductive filament consists of four steps: (i) mixing graphite and PLA in a heated reflux system; (ii) recrystallization of the composite; (iii) drying and; (iv) extrusion. The produced filament was used for the manufacture of electrochemical 3D printed sensors. The filament and sensor were characterized by physicochemical techniques, such as SEM, TGA, Raman, FTIR as well as electrochemical techniques (EIS and CV). Finally, as a proof-of-concept, the fabricated 3D-printed sensor was applied for the determination of uric acid and dopamine in synthetic urine and used as a platform for the development of a biosensor for the detection of SARS-CoV-2. The developed sensors, without pre-treatment, provided linear ranges of 0.5-150.0 and 5.0-50.0 μmol L^-1, with low LOD values (0.07 and 0.11 μmol L^-1), for uric acid and dopamine, respectively. The developed biosensor successfully detected SARS-CoV-2 S protein, with a linear range from 5.0 to 75.0 nmol L^-1 (0.38 μg mL^-1 to 5.74 μg mL^-1) and LOD of 1.36 nmol L^-1 (0.10 μg mL^-1) and sensitivity of 0.17 μA nmol^-1 L (0.01 μA μg^-1 mL). Therefore, the lab-made produced and the ready-to-use conductive filament is promising and can become an alternative route for the production of different 3D electrochemical (bio)sensors and other types of conductive devices by 3D printing.

Influence of filament aging and conductive additive in 3D printed sensors

3D printing technology combined with electrochemical techniques have allowed the development of versatile and low-cost devices. However, some aspects need to be considered for the good quality and useful life of the sensors. In this work, we have demonstrated herein that the filament aging, the conductive material, and the activation processes (post-treatments) can influence the surface characteristics and the electrochemical performance of the 3D printed sensors. Commercial filaments and 3D printed sensors were morphologically, thermally, and electrochemically analyzed. The activated graphene-based (Black Magic®) sensor showed the best electrochemical response, compared to the carbon black-filament (Proto-Pasta®). In addition, we have proven that filament aging harms the performance of the sensors since the electrodes produced with three years old filament had a considerably lower intra-days reproducibility. Finally, the activated graphene-based sensor has shown the best performance for the electrochemical detection of bisphenol A, demonstrating the importance of evaluating and control the characteristics and quality of filaments to improve the mechanical, conductive, and electrochemical performance of 3D printed sensors.

Exploration of defined 2-dimensional working electrode shapes through additive manufacturing

In this work, the electrochemical response of different morphologies (shapes) and dimensions of additively manufactured (3D-printing) carbon black(CB)/poly-lactic acid (PLA) electrodes are reported.

Hierarchical Atomic Layer Deposited V2 O5 on 3D Printed Nanocarbon Electrodes for High-Performance Aqueous Zinc-Ion Batteries

Aqueous rechargeable zinc-ion batteries (ARZIBs) are promising energy storage systems owing to their ecofriendliness, safety, and cost-efficiency. However, the sluggish Zn²⁺ diffusion kinetics originated from its inherent large atomic mass and high polarization remains an ongoing challenge. To this end, electrodes with 3D architectures and high porosity are highly desired. This work reports a rational design and fabrication of hierarchical core-shell structured cathodes (3D@V₂ O₅ ) for ARZIBs by integrating fused deposition modeling (FDM) 3D-printing with atomic layer deposition (ALD). The 3D-printed porous carbon network provides an entangled electron conductive core and interconnected ion diffusion channels, whereas ALD-coated V₂ O₅ serves as an active shell without sacrificing the porosity for facilitated Zn²⁺ diffusion. This endows the 3D@V₂ O₅ cathode with high specific capacity (425 mAh g^-1 at 0.3 A g^-1 ), competitive energy and power densities (316 Wh Kg^-1 at 213 W kg^-1 and 163 Wh Kg^-1 at 3400 W kg^-1 ), and good rate performance (221 mAh g^-1 at 4.8 A g^-1 ). The developed 3D@V₂ O₅ cathode provides a promising model for customized and scalable battery electrode engineering technology. As the ALD-coated layer determines the functional properties, the proposed strategy shows a promising prospect of FDM 3D printing using 1D carbon materials for future energy storage.

High-Impact Polystyrene Reinforced with Reduced Graphene Oxide as a Filament for Fused Filament Fabrication 3D Printing

Graphene and its derivatives, such as graphene oxide (GO) or reduced graphene oxide (rGO), due to their properties, have been enjoying great interest for over two decades, particularly in the context of additive manufacturing (AM) applications in recent years. High-impact polystyrene (HIPS) is a polymer used in 3D printing technology due to its high dimensional stability, low cost, and ease of processing. However, the ongoing development of AM creates the need to produce modern feedstock materials with better properties and functionality. This can be achieved by introducing reduced graphene oxide into the polymer matrix. In this study, printable composite filaments were prepared and characterized in terms of morphology and thermal and mechanical properties. Among the obtained HIPS/rGO composites, the filament containing 0.5 wt% of reduced graphene oxide had the best mechanical properties. Its tensile strength increased from 19.84 to 22.45 MPa, for pure HIPS and HIPS-0.5, respectively. Furthermore, when using the HIPS-0.5 filament in the printing process, no clogging of the nozzle was observed, which may indicate good dispersion of the rGO in the polymer matrix.

Recent Advances on 2D Materials towards 3D Printing

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

3D printed silicon-few layer graphene anode for advanced Li-ion batteries

The printing of three-dimensional (3D) porous electrodes for Li-ion batteries is considered a key driver for the design and realization of advanced energy storage systems. While different 3D printing techniques offer great potential to design and develop 3D architectures, several factors need to be addressed to print 3D electrodes, maintaining an optimal trade-off between electrochemical and mechanical performances. Herein, we report the first demonstration of 3D printed Si-based electrodes fabricated using a simple and cost-effective fused deposition modelling (FDM) method, and implemented as anodes in Li-ion batteries. To fulfil the printability requirement while maximizing the electrochemical performance, the composition of the FDM filament has been engineered using polylactic acid as the host polymeric matrix, a mixture of carbon black-doped polypyrrole and wet-jet milling exfoliated few-layer graphene flakes as conductive additives, and Si nanoparticles as the active material. The creation of a continuous conductive network and the control of the structural properties at the nanoscale enabled the design and realization of flexible 3D printed anodes, reaching a specific capacity up to ∼345 mA h g-1 at the current density of 20 mA g-1, together with a capacity retention of 96% after 350 cycles. The obtained results are promising for the fabrication of flexible polymeric-based 3D energy storage devices to meet the challenges ahead for the design of next-generation electronic devices.

Versatile Design of Functional Organic-Inorganic 3D-Printed (Opto)Electronic Interfaces with Custom Catalytic Activity

The ability to combine organic and inorganic components in a single material represents a great step toward the development of advanced (opto)electronic systems. Nowadays, 3D-printing technology has generated a revolution in the rapid prototyping and low-cost fabrication of 3D-printed electronic devices. However, a main drawback when using 3D-printed transducers is the lack of robust functionalization methods for tuning their capabilities. Herein, a simple, general and robust in situ functionalization approach is reported to tailor the capabilities of 3D-printed nanocomposite carbon/polymer electrode (3D-nCE) surfaces with a battery of functional inorganic nanoparticles (FINPs), which are appealing active units for electronic, optical and catalytic applications. The versatility of the resulting functional organic-inorganic 3D-printed electronic interfaces is provided in different pivotal areas of electrochemistry, including i) electrocatalysis, ii) bio-electroanalysis, iii) energy (storage and conversion), and iv) photoelectrochemical applications. Overall, the synergism of combining the transducing characteristics of 3D-nCEs with the implanted tuning surface capabilities of FINPs leads to new/enhanced electrochemical performances when compared to their bare 3D-nCE counterparts. Accordingly, this work elucidates that FINPs have much to offer in the field of 3D-printing technology and provides the bases toward the green fabrication of functional organic-inorganic 3D-printed (opto)electronic interfaces with custom catalytic activity.

Synthesis of 3D graphene-based materials and their applications for removing dyes and heavy metals

Contamination of water streams by dyes and heavy metals has become a major problem due to their persistence, accumulation, and toxicity. Therefore, it is essential to eliminate and/or reduce these contaminants before discharge into the natural environment. In recent years, 3D graphene has drawn intense research interests owing to its large surface area, superior charge conductivity, and thermal conductivity properties. Due to their unique surface and structural properties, 3D graphene-based materials (3D GBMs) are regarded as ideal adsorbents for decontamination and show great potential in wastewater or exhaust gas treatment. Here, this minireview summarizes the recent progress on 3D GBMs synthesis and their applications for adsorbing dyes and heavy metals from wastewater based on the structures and properties of 3D GBMs, which provides valuable insights into 3D GBMs' application in the environmental field.

Aqueous Inks of Pristine Graphene for 3D Printed Microsupercapacitors with High Capacitance

Three-dimensional (3D) printing is gaining importance as a sustainable route for the fabrication of high-performance energy storage devices. It enables the streamlined manufacture of devices with programmable geometry at different length scales down to micron-sized dimensions. Miniaturized energy storage devices are fundamental components for on-chip technologies to enable energy autonomy. In this work, we demonstrate 3D printed microsupercapacitor electrodes from aqueous inks of pristine graphene without the need of high temperature processing and functional additives. With an intrinsic electrical conductivity of ∼1370 S m^-1 and rationally designed architectures, the symmetric microsupercapacitors exhibit an exceptional areal capacitance of 1.57 F cm^-2 at 2 mA cm^-2 which is retained over 72% after repeated voltage holding tests. The areal power density (0.968 mW cm^-2) and areal energy density (51.2 μWh cm^-2) outperform the ones of previously reported carbon-based supercapacitors which have been either 3D or inkjet printed. Moreover, a current collector-free interdigitated microsupercapacitor combined with a gel electrolyte provides electrochemical performance approaching the one of devices with liquid-like ion transport properties. Our studies provide a sustainable and low-cost approach to fabricate efficient energy storage devices with programmable geometry.

High Performance Tunable Catalysts Prepared by Using 3D Printing

Honeycomb monoliths are the preferred supports in many industrial heterogeneous catalysis reactions, but current extrusion synthesis only allows obtaining parallel channels. Here, we demonstrate that 3D printing opens new design possibilities that outperform conventional catalysts. High performance carbon integral monoliths have been prepared with a complex network of interconnected channels and have been tested for carbon dioxide hydrogenation to methane after loading a Ni/CeO₂ active phase. CO₂ methanation rate is enhanced by 25% at 300 °C because the novel design forces turbulent flow into the channels network. The methodology and monoliths developed can be applied to other heterogeneous catalysis reactions, and open new synthesis options based on 3D printing to manufacture tailored heterogeneous catalysts.