Robust Underwater Oil-Repellent Biomimetic Ceramic Surfaces: Combining the Stability and Reproducibility of Functional Structures

Robust underwater oil-repellent materials combining high mechanical strength and durability with superwettability and low oil adhesion are needed to build oil-repellent devices able to work in water, to manipulate droplet behavior, etc. However, combining all of these properties within a single, durable material remains a challenge. Herein, we fabricate a robust underwater oil-resistant material (Al₂O₃) with all of the above properties by gel casting. The micro/nanoceramic particles distributed on the surface endow the material with excellent underwater superoleophobicity (∼160°) and low oil adhesion (<4 μN). In addition, the substrate exhibits typical ceramic characteristics such as good antiacid/alkali properties, high salt resistance, and high load tolerance. These excellent properties make the material not only applicable to various liquid environments but also resistant to the impact of particles and other physical damage. More importantly, the substrate could still exhibit underwater superoleophobicity after being worn under specific conditions, as wear will create new surfaces with similar particle size distribution. This approach is easily scalable for mass production, which could open a pathway for the fabrication of practical underwater long-lasting functional interfacial materials.

Tough Bioinspired Composites That Self-Report Damage

The increasing use of lightweight composite materials in structural applications requires the development of new damage monitoring technologies to ensure their safe use and prevent accidents. Although several molecular strategies have been proposed to report damage in polymers through mechanochromic responses, these approaches have not yet been translated into lightweight bioinspired composites for load-bearing applications. Here, we report on the development of bioinspired laminates of alternating polymer and nacre-like layers that combine optical translucency, high fracture toughness, and damage-reporting capabilities. The composites signal damage via a fluorescence color change that arises from the force activation of mechanophore molecules embedded in the material's polymer phase. A quantitative correlation between the applied strain and the fluorescence intensity was successfully established. We demonstrate that optical imaging of mechanically loaded composites allows for the localized detection of damage prior to fracture. This fluorescence-based self-reporting mechanism offers a promising approach for the early detection of damage in lightweight structural composites and can serve as a useful tool for the analysis of fracture processes in bulk transparent materials.

Architectured ZnO-Cu particles for facile manufacturing of integrated Li-ion electrodes

Designing electrodes with tailored architecture is an efficient mean to enhance the performance of metal-ion batteries by minimizing electronic and ionic transport limitations and increasing the fraction of active material in the electrode. However, the fabrication of architectured electrodes often involves multiple laborious steps that are not directly scalable to current manufacturing platforms. Here, we propose a processing route in which Cu-coated ZnO powders are directly shaped into architectured electrodes using a simple uniaxial pressing step. Uniaxial pressing leads to a percolating Cu phase with enhanced electrical conductivity between the active ZnO particles and improved mechanical stability, thus dispensing the use of carbon-based additives and polymeric binders in the electrode composition. The additive-free percolating copper network obtained upon pressing leads to highly loaded integrated anodes displaying volumetric charge capacity 6-10 fold higher than Cu-free ZnO films and that matches the electrochemical performance reported for advanced cathode structures. Achieving this high charge capacity using a readily available pressing tool makes this approach a promising route for the facile manufacturing of high-performance electrodes at large industrial scales.

Broadband, High-Temperature Stable Reflector for Aerospace Thermal Radiation Protection

A simple and thermally stable photonic heterostructure exhibiting high average reflectivity (⟨R⟩ ≈ 88.8%) across a broad wavelength range (920-1450 nm) is presented. The design combines a thin, highly reflective and broadband metallic substrate (Ta) with an optimized dielectric coating (10 layers) to create an enhanced reflector with improved optical and thermal properties compared to its constituents. The heterostructure exhibits temperature-reversible reflective properties up to 1000 °C. In order to take advantage of the high reflectivity and temperature stable properties of this coating, in a wide range of non-photonic composite materials, we have fabricated heterostructure platelets as additives. By impregnating these additives into other types of materials, their response can be photonically enhanced.  Platelets of such a heterostructure have been introduced inside an organic matrix to increase its broadband reflection performance. The platelet-impregnated matrix displays an average reflectivity improvement from 5% to an average of 55% over a 1000 nm range, making it a suitable additive for next generation thermal protection systems (TPS).

Transparent and tough bulk composites inspired by nacre

Materials combining optical transparency and mechanical strength are highly demanded for electronic displays, structural windows and in the arts, but the oxide-based glasses currently used in most of these applications suffer from brittle fracture and low crack tolerance. We report a simple approach to fabricate bulk transparent materials with a nacre-like architecture that can effectively arrest the propagation of cracks during fracture. Mechanical characterization shows that our glass-based composites exceed up to a factor of 3 the fracture toughness of common glasses, while keeping flexural strengths comparable to transparent polymers, silica- and soda-lime glasses. Due to the presence of stiff reinforcing platelets, the hardness of the obtained composites is an order of magnitude higher than that of transparent polymers. By implementing biological design principles into glass-based materials at the microscale, our approach opens a promising new avenue for the manufacturing of structural materials combining antagonistic functional properties.

Design of textured multi-layered structures via magnetically assisted slip casting

Multi-layered composites in nature often show functional properties that are determined by the specific orientation of inorganic building blocks within each layer. The shell of bivalve molluscs and the exoskeleton of crustaceans constitute prominent examples. An effective approach to artificially produce textured microstructures inspired by such complex composites is magnetically assisted slip casting (MASC). MASC is a colloidal process in which anisotropic particles are magnetically oriented at arbitrarily defined angles and collected at the surface of a porous mould to grow the material in an additive manner. Whereas a number of proof-of-concept studies have established the potential of the technique, the full design space available for MASC-fabricated structures, and the limits of the approach, have so far not been explored systematically. To fill this gap, we have studied both theoretically and experimentally the various torques that act on the particles at the different stages of the assembly process. We define the boundary conditions of the MASC process for magnetically responsive alumina platelets suspended in a low-viscosity aqueous suspension, considering the composition of the colloidal suspension and the dynamics of the particle alignment process under a rotating magnetic field. These findings lead to design guidelines for the fabrication of bio-inspired composites with customized multi-scale structures for a broad range of applications.

3D printing of sacrificial templates into hierarchical porous materials

Hierarchical porous materials are widespread in nature and find an increasing number of applications as catalytic supports, biological scaffolds and lightweight structures. Recent advances in additive manufacturing and 3D printing technologies have enabled the digital fabrication of porous materials in the form of lattices, cellular structures and foams across multiple length scales. However, current approaches do not allow for the fast manufacturing of bulk porous materials featuring pore sizes that span broadly from macroscopic dimensions down to the nanoscale. Here, ink formulations are designed and investigated to enable 3D printing of hierarchical materials displaying porosity at the nano-, micro- and macroscales. Pores are generated upon removal of nanodroplets and microscale templates present in the initial ink. Using particles to stabilize the droplet templates is key to obtain Pickering nanoemulsions that can be 3D printed through direct ink writing. The combination of such self-assembled templates with the spatial control offered by the printing process allows for the digital manufacturing of hierarchical materials exhibiting thus far inaccessible multiscale porosity and complex geometries.

3D Printing of Materials with Tunable Failure via Bioinspired Mechanical Gradients

Mechanical gradients are useful to reduce strain mismatches in heterogeneous materials and thus prevent premature failure of devices in a wide range of applications. While complex graded designs are a hallmark of biological materials, gradients in manmade materials are often limited to 1D profiles due to the lack of adequate fabrication tools. Here, a multimaterial 3D-printing platform is developed to fabricate elastomer gradients spanning three orders of magnitude in elastic modulus and used to investigate the role of various bioinspired gradient designs on the local and global mechanical behavior of synthetic materials. The digital image correlation data and finite element modeling indicate that gradients can be effectively used to manipulate the stress state and thus circumvent the weakening effect of defect-rich interfaces or program the failure behavior of heterogeneous materials. Implementing this concept in materials with bioinspired designs can potentially lead to defect-tolerant structures and to materials whose tunable failure facilitates repair of biomedical implants, stretchable electronics, or soft robotics.

Addendum: Magnetically assisted slip casting of bioinspired heterogeneous composites

This corrects the article DOI: 10.1038/nmat4419.

Corrigendum: Strong, tough and stiff bioinspired ceramics from brittle constituents

This corrects the article DOI: 10.1038/nmat3915.

Mineral Nano-Interconnectivity Stiffens and Toughens Nacre-like Composite Materials

Bulk nacre-like composites with mineral nano-interconnectivity at the same length scale as in the biological material are produced using magnetic alignment and selective sintering techniques. These materials display stiffness and strength levels comparable to that of continuous fiber composites with the advantage of easier processability inherent of discontinuous composites. This opens new possibilities to produce parts with more complex designs.

Magnetically assisted slip casting of bioinspired heterogeneous composites

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

Self-assembly of faceted particles triggered by a moving ice front

The possibility to align and organize faceted particles in the bulk offers intriguing possibilities for the design and discovery of materials and architectures exhibiting novel functional properties. The growth of ice crystals can be used to trigger the self-assembly of large, anisotropic particles and consequently to obtain three-dimensional porous materials of large dimensions in a limited amount of time. These mechanisms have not been explored so far due to the difficulty to experimentally investigate these systems. Here we elucidate the self-assembly mechanisms of faceted particles driven by ice growth by a combination of X-ray holotomography and discrete element modeling, providing insights into both the dynamics of self-assembly and their final packing. The encapsulation of particles is the result of a delicate balance between the force exerted by the percolating network of concentrated particles and the force exerted by the moving interface. We illustrate the benefits of such self-assembly for thermal management composite materials.

Strong, tough and stiff bioinspired ceramics from brittle constituents

High strength and high toughness are usually mutually exclusive in engineering materials. In ceramics, improving toughness usually relies on the introduction of a metallic or polymeric ductile phase, but this decreases the material's strength and stiffness as well as its high-temperature stability. Although natural materials that are both strong and tough rely on a combination of mechanisms operating at different length scales, the relevant structures have been extremely difficult to replicate. Here, we report a bioinspired approach based on widespread ceramic processing techniques for the fabrication of bulk ceramics without a ductile phase and with a unique combination of high strength (470 MPa), high toughness (22 MPa m(1/2)), and high stiffness (290 GPa). Because only mineral constituents are needed, these ceramics retain their mechanical properties at high temperatures (600 °C). Our bioinspired, material-independent approach should find uses in the design and processing of materials for structural, transportation and energy-related applications.