3D printed architected conducting polymer hydrogels

Understanding the Current Distribution and Mass Transport Properties in 3D-Printed Architected Flow-Through Electrodes

Architected materials offer promising advancements in energy storage by enabling highly customizable, high-surface-area, ordered, and low-defect porous structures. This study investigates the current distribution and mass transport within complex 3D-printed lattice electrodes under flow-through conditions. Conductive lattices were fabricated using microstereolithography followed by pyrolytic carbonization. Lattice geometry effects were analyzed by varying the unit cell type [simple cubic (SC), body- and face-centered cubic (BCC/FCC), IsoTruss, and Octet], porosity, and current density. Current distribution uniformity was investigated using a model high-efficiency copper deposition reaction. Local film thickness distributions were predicted using a numerical model and validated experimentally using micro-X-ray computed tomography. Scaling relationships for informing electrochemical reaction conditions and current uniformity are formulated as a modified lattice-based Wagner number (Wa Lattice) and a corresponding inverse Damkohler number (Da Lattice -1). Validated models reveal that mass-transfer coefficients scale as Octet > IsoTruss > FCC ∼ BCC > SC. Inertial effects become significant at Reynolds number Re > 3 and are particularly pronounced in Octet structures due to an abundance of struts oriented away from the fluid flow direction. The study underscores the importance of electrode engineering and process conditions necessary to tailor mass transport and current uniformities to various device applications.

One-Step Digital Light Processing 3D Printing of Robust, Conductive, Shape-Memory Hydrogel for Customizing High-Performance Soft Devices

Mechanically robust and electrically conductive hydrogels hold significant promise for flexible device applications. However, conventional fabrication methods such as casting or injection molding meet challenges in delivering hydrogel objects with complex geometric structures and multicustomized functionalities. Herein, a 3D printable hydrogel with excellent mechanical properties and electrical conductivity is implemented via a facile one-step preparation strategy. With vat polymerization 3D printing technology, the hydrogel can be solidified based on a hybrid double-network mechanism involving in situ chemical and physical dual cross-linking. The hydrogel consists of two chemical networks including covalently cross-linked poly(acrylamide-co-acrylic acid) and chitosan, and zirconium ions are induced to form physically cross-linked metal-coordination bonds across both chemical networks. The 3D-printed hydrogel exhibits multiple excellent functionalities including enhanced mechanical properties (680% stretchability, 15.1 MJ/m3 toughness, and 7.30 MPa tensile strength), rapid printing speed (0.7-3 s/100 μm), high transparency (91%), favorable ionic conductivity (0.75 S/m), large strain gauge factor (≥7), and fast solvent transfer induced phase separation (in ∼3 s), which enable the development of high-performance flexible wearable sensors, shape memory actuators, and soft pneumatic robotics. The 3D printable multifunctional hydrogel provides a novel path for customizing next-generation intelligent soft devices.

Recent Advances in the 3D Printing of Conductive Hydrogels for Sensor Applications: A Review

Conductive hydrogels, known for their flexibility, biocompatibility, and conductivity, have found extensive applications in fields such as healthcare, environmental monitoring, and soft robotics. Recent advancements in 3D printing technologies have transformed the fabrication of conductive hydrogels, creating new opportunities for sensing applications. This review provides a comprehensive overview of the advancements in the fabrication and application of 3D-printed conductive hydrogel sensors. First, the basic principles and fabrication techniques of conductive hydrogels are briefly reviewed. We then explore various 3D printing methods for conductive hydrogels, discussing their respective strengths and limitations. The review also summarizes the applications of 3D-printed conductive hydrogel-based sensors. In addition, perspectives on 3D-printed conductive hydrogel sensors are highlighted. This review aims to equip researchers and engineers with insights into the current landscape of 3D-printed conductive hydrogel sensors and to inspire future innovations in this promising field.

Conductive Polymer-Based Hydrogels for Wearable Electrochemical Biosensors

Hydrogels are gaining popularity for use in wearable electronics owing to their inherent biomimetic characteristics, flexible physicochemical properties, and excellent biocompatibility. Among various hydrogels, conductive polymer-based hydrogels (CP HGs) have emerged as excellent candidates for future wearable sensor designs. These hydrogels can attain desired properties through various tuning strategies extending from molecular design to microstructural configuration. However, significant challenges remain, such as the limited strain-sensing range, significant hysteresis of sensing signals, dehydration-induced functional failure, and surface/interfacial malfunction during manufacturing/processing. This review summarizes the recent developments in polymer-hydrogel-based wearable electrochemical biosensors over the past five years. Initially serving as carriers for biomolecules, polymer-hydrogel-based sensors have advanced to encompass a wider range of applications, including the development of non-enzymatic sensors facilitated by the integration of nanomaterials such as metals, metal oxides, and carbon-based materials. Beyond the numerous existing reports that primarily focus on biomolecule detection, we extend the scope to include the fabrication of nanocomposite conductive polymer hydrogels and explore their varied conductivity mechanisms in electrochemical sensing applications. This comprehensive evaluation is instrumental in determining the readiness of these polymer hydrogels for point-of-care translation and state-of-the-art applications in wearable electrochemical sensing technology.

Photocuring 3D Printing of Hydrogels: Techniques, Materials, and Applications in Tissue Engineering and Flexible Devices

Photocuring 3D printing of hydrogels, with sophisticated, delicate structures and biocompatibility, attracts significant attention by researchers and possesses promising application in the fields of tissue engineering and flexible devices. After years of development, photocuring 3D printing technologies and hydrogel inks make great progress. Herein, the techniques of photocuring 3D printing of hydrogels, including direct ink writing (DIW), stereolithography (SLA), digital light processing (DLP), continuous liquid interface production (CLIP), volumetric additive manufacturing (VAM), and two photon polymerization (TPP) are reviewed. Further, the raw materials for hydrogel inks (photocurable polymers, monomers, photoinitiators, and additives) and applications in tissue engineering and flexible devices are also reviewed. At last, the current challenges and future perspectives of photocuring 3D printing of hydrogels are discussed.

Seamless Integration of Conducting Hydrogels in Daily Life: From Preparation to Wearable Application

Conductive hydrogels (CHs) have received significant attention for use in wearable devices because they retain their softness and flexibility while maintaining high conductivity. CHs are well suited for applications in skin-contact electronics and biomedical devices owing to their high biocompatibility and conformality. Although highly conductive hydrogels for smart wearable devices are extensively researched, a detailed summary of the outstanding results of CHs is required for a comprehensive understanding. In this review, the recent progress in the preparation and fabrication of CHs is summarized for smart wearable devices. Improvements in the mechanical, electrical, and functional properties of high-performance wearable devices are also discussed. Furthermore, recent examples of innovative and highly functional devices based on CHs that can be seamlessly integrated into daily lives are reviewed.

An effective DLP 3D printing strategy of high strength and toughness cellulose hydrogel towards strain sensing

Photocurable 3D printing technology has outperformed extrusion-based 3D printing technology in material adaptability, resolution, and printing rate, yet is still limited by the insecure preparation and selection of photoinitiators and thus less reported. In this work, we developed a printable hydrogel that can effectively facilitate various solid or hollow structures and even lattice structures. The chemical and physical dual-crosslinking strategy combined with cellulose nanofibers (CNF) significantly improved the strength and toughness of photocurable 3D printed hydrogels. In this study, the tensile breaking strength, Young's modulus, and toughness of poly(acrylamide-co-acrylic acid)_D/cellulose nanofiber (PAM-co-PAA)_D/CNF hydrogels were 375 %, 203 % and 544 % higher than those of the traditional single chemical crosslinked (PAM-co-PAA)_S hydrogels, respectively. Notably, its outstanding compressive elasticity enabled it to recover under 90 % strain compression (about 4.12 MPa). Resultantly, the proposed hydrogel can be utilized as a flexible strain sensor to monitor the motions of human movements, such as the bending of fingers, wrists, and arms, and even the vibration of a speaking throat. The output of electrical signals can still be collected through strain even under the condition of energy shortage. In addition, photocurable 3D printing technology can provide customized services for hydrogel-based e-skin, such as hydrogel-based bracelets, fingerstall, and finger joint sleeves.

Recent Advances and Progress of Conducting Polymer-Based Hydrogels in Strain Sensor Applications

Conducting polymer-based hydrogels (CPHs) are novel materials that take advantage of both conducting polymers and three-dimensional hydrogels, which endow them with great electrical properties and excellent mechanical features. Therefore, CPHs are considered as one of the most promising platforms for employing wearable and stretchable strain sensors in practical applications. Herein, we provide a critical review of distinct features and preparation technologies and the advancements in CPH-based strain sensors for human motion and health monitoring applications. The fundamentals, working mechanisms, and requirements for the design of CPH-based strain sensors with high performance are also summarized and discussed. Moreover, the recent progress and development strategies for the implementation of CPH-based strain sensors are pointed out and described. It has been surmised that electronic skin (e-skin) sensors are the upward tendency in the development of CPHs for wearable strain sensors and human health monitoring. This review will be important scientific evidence to formulate new approaches for the development of CPH-based strain sensors in the present and in the future.

Influence of the Nature and Structure of Polyelectrolyte Cryogels on the Polymerization of (3,4-Ethylenedioxythiophene) and Spectroscopic Characterization of the Composites

Conductive hydrogels are polymeric materials that are promising for bioelectronic applications. In the present study, a complex based on sulfonic cryogels and poly(3,4-ethylenedioxythiophene) (PEDOT) was investigated as an example of a conductive hydrogel. Preparation of polyacrylate cryogels of various morphologies was carried out by cryotropic gelation of 3-sulfopropyl methacrylate and sulfobetaine methacrylate in the presence of functional comonomers (2-hydroxyethyl methacrylate and vinyl acetate). Polymerization of 3,4-ethylenedioxythiophene in the presence of several of the above cryogels occurred throughout the entire volume of each polyelectrolyte cryogel because of its porous structure. Structural features of cryogel@PEDOT complexes in relation to their electrochemical properties were investigated. It was shown that poly(3,4-ethylenedioxythiophene) of a linear conformation was formed in the presence of a cryogel based on sulfobetaine methacrylate, while minimum values of charge-transfer resistance were observed in those complexes, and electrochemical properties of the complexes did not depend on diffusion processes.

3D-Printed Electroactive Hydrogel Architectures with Sub-100 µm Resolution Promote Myoblast Viability

3D-printed hydrogel scaffolds functionalized with conductive polymers have demonstrated significant potential in regenerative applications for their structural tunability, physiochemical compatibility, and electroactivity. Controllably generating conductive hydrogels with fine features, however, has proven challenging. Here, micro-continuous liquid interface production (μCLIP) method is utilized to 3D print poly(2-hydroxyethyl methacrylate) (pHEMA) hydrogels. With a unique in-situ polymerization approach, a sulfonated monomer is first incorporated into the hydrogel matrix and subsequently polymerized into a conjugated polyelectrolyte, poly(4-(2,3-dihydro-thieno[3,4-b][1,4]dioxin-2-ylmethoxy)-butane-1 sulfonic acid sodium salt (PEDOT-S). Rod structures are fabricated at different crosslinking levels to investigate PEDOT-S incorporation and its effect on bulk hydrogel electronic and mechanical properties. After demonstrating that PEDOT-S does not significantly compromise the structures of the bulk material, pHEMA scaffolds are fabricated via μCLIP with features smaller than 100 µm. Scaffold characterization confirms PEDOT-S incorporation bolstered conductivity while lowering overall modulus. Finally, C2C12 myoblasts are seeded on PEDOT-pHEMA structures to verify cytocompatibility and the potential of this material in future regenerative applications. PEDOT-pHEMA scaffolds promote increased cell viability relative to their non-conductive counterparts and differentially influence cell organization. Taken together, this study presents a promising new approach for fabricating complex conductive hydrogel structures for regenerative applications.

3D Printing Technologies in Biosensors Production: Recent Developments

Recent advances in 3D printing technologies and materials have enabled rapid development of innovative sensors for applications in different aspects of human life. Various 3D printing technologies have been adopted to fabricate biosensors or some of their components thanks to the advantages of these methodologies over the traditional ones, such as end-user customization and rapid prototyping. In this review, the works published in the last two years on 3D-printed biosensors are considered and grouped on the basis of the 3D printing technologies applied in different fields of application, highlighting the main analytical parameters. In the first part, 3D methods are discussed, after which the principal achievements and promising aspects obtained with the 3D-printed sensors are reported. An overview of the recent developments on this current topic is provided, as established by the considered works in this multidisciplinary field. Finally, future challenges on the improvement and innovation of the 3D printing technologies utilized for biosensors production are discussed.