This study addresses the challenges of efficient, large-scale production of flexible transparent conducting electrodes (TCEs). We fabricate TCEs on polyethylene terephthalate (PET) substrates using a high-speed roll-to-roll (R2R) compatible method that combines gravure printing and photonic curing. The hybrid TCEs consist of Ag metal bus lines (Ag MBLs) coated with silver nanowires (AgNWs) and indium zinc oxide (IZO) layers. All materials are solutions deposited at speeds exceeding 10 m/min using gravure printing. We conduct a systematic study to optimize coating parameters and tune solvent composition to achieve a uniform AgNW network. The entire stack undergoes photonic curing, a low-energy annealing method that can be completed at high speeds and will not damage the plastic substrates. The resulting hybrid TCEs exhibit a transmittance of 92% averaged from 400 nm to 1100 nm and a sheet resistance of 11 Ω/sq. Mechanical durability is tested by bending the hybrid TCEs to a strain of 1% for 2000 cycles. The results show a minimal increase (<5%) in resistance. The high-throughput potential is established by showing that each hybrid TCE fabrication step can be completed at 30 m/min. We further fabricate methylammonium lead iodide solar cells to demonstrate the practical use of these TCEs, achieving an average power conversion efficiency (PCE) of 13%. The high-performance hybrid TCEs produced using R2R-compatible processes show potential as a viable choice for replacing vacuum-deposited indium tin oxide films on PET.

A simple method is developed to produce free-standing films of polypyrrole (PPy) in one step. It consists of the interfacial polymerization (without surfactants) of pyrrole (dissolved in chloroform) with an oxidant (ammonium persulfate, dissolved in water). It is observed that the area of the formed film only depends on the size of the interface, achieving the manufacture of PPy films of up to 300 cm2, with a thickness of 200 microns. Transmission electron microscopy (TEM) images show the presence of superimposed nanoplatelets of ca. 100 nm main axis. These nanoparticles seem to aggregate in two dimensions to form the free-standing film. Scanning electron microscopy (SEM) shows a compact surface with nanowires decorating the surface. PPy films show an electrical conductivity of 63 (±3) S cm−1. PPy conductive films are then applied in the construction of an antenna that shows a response in two bands: at 1.52 GHz (−13.85 dB) and at 3.50 GHz (−33.55 dB). The values are comparable to those of other antennas built with different PPy films. The simple synthesis of large-area PPy films in a single step would allow the fabrication of large quantities of electronic elements (e.g., sensors) with uniform properties in a short time.

A national energy crisis has emerged in South Africa due to the country’s increasing energy needs in recent years. The reliance on fossil fuels, especially oil and gas, is unsustainable due to scarcity, emissions, and environmental repercussions. Researchers from all over the world have recently concentrated their efforts on finding carbon-free, renewable, and alternative energy sources and have investigated microbiology and biotechnology as a potential remedy. The usage of microbial electrolytic cells (MECs) and microbial fuel cells (MFCs) is one method for resolving the problem. These technologies are evolving as viable options for hydrogen and bioenergy production. The renewable energy technologies initiative in South Africa, which is regarded as a model for other African countries, has developed in the allocation of over 6000 MW of generation capacity to bidders across several technologies, primarily wind and solar. With a total investment value of R33.7 billion, the Eastern Cape’s renewable energy initiatives have created 18,132 jobs, with the province awarded 16 wind farms and one solar energy farm. Utilizing wastewater as a source of energy in MFCs has been recommended as most treatments, such as activated sludge processes and trickling filter plants, require roughly 1322 kWh per million gallons, whereas MFCs only require a small amount of external power to operate. The cost of wastewater treatment using MFCs for an influent flow of 318 m3 h−1 has been estimated to be only 9% (USD 6.4 million) of the total cost of treatment by a conventional wastewater treatment plant (USD 68.2 million). Currently, approximately 500 billion cubic meters of hydrogen (H2) are generated worldwide each year, exhibiting a growth rate of 10%. This production primarily comes from natural gas (40%), heavy oils and naphtha (30%), coal (18%), electrolysis (4%), and biomass (1%). The hydrogen produced is utilized in the manufacturing of ammonia (49%), the refining of petroleum (37%), the production of methanol (8%), and in a variety of smaller applications (6%). Considering South Africa’s energy issue, this review article examines the production of wastewater and its impacts on society as a critical issue in the global scenario and as a source of green energy.

Effective high-aspect-ratio molds that minimize vacuum processes are becoming increasingly important for producing metalenses and other devices. To fabricate a high-aspect-ratio structure, a metal film must be used as a mask for dry etching, typically achieved via vacuum deposition. To avoid this vacuum process, we devised a method to develop an etching mask in the air using silver ink. The manufacturing method involved filling the mold with silver ink, baking it, removing silver from the convex parts of the mold with a polyethylene terephthalate film, and placing silver from the concave parts of the mold on top of the ultraviolet (UV)-cured resin using ultraviolet-nanoimprint lithography. The transferred pattern had silver on the convex parts, which was used as a mask for the oxygen dry etching of the UV-curable resin. Consequently, high-aspect-ratio resin shapes were obtained from three types of nano- and micromolds. Additionally, a high-aspect-ratio resin with silver was used as a replica mold to form a silver pattern. This process is effective and allows high-aspect-ratio patterns to be obtained from master molds.

This research discusses the fabrication of a nickel matrix nanocomposite reinforced with in situ synthesized layered Ni3Al intermetallics using mechanical alloying (MA) and spark plasma sintering (SPS). In contrast to ex situ methods that frequently produce weak interfaces, the in situ approach enhances bonding and mechanical performance by using layered Ni3Al reinforcements with excellent deformation resistance and load-bearing potential. Twenty-hour milled Ni-Al powders were annealed at 700 °C and consolidated using SPS, achieving approximately 96% theoretical density. The nanocomposite showed exceptional mechanical properties, with a hardness of 350 ± 15 HV in contrast to 200 ± 5 HV for pure Ni, along with higher wear resistance and reduced wear track depth. These improvements resulted from microstructural refinement and the development of hard intermetallic phases. X-ray diffraction (XRD) and transmission electron microscopy (TEM) confirmed the formation of a homogeneous layered Ni3Al structure inside the matrix, showing a crystallite size of around 40 nm post-milling. Layered reinforcements enhanced matrix–reinforcement interactions, thereby minimizing common challenges in traditional composites. This innovative production technique highlights the future potential of Ni3Al-reinforced nanocomposites as high-performance materials for advanced engineering applications, combining outstanding mechanical and tribological properties with strong structural integrity.

The pervasive use of screens, averaging nearly 7 h per day globally between mobile phones, computers, notebooks and TVs, has sparked a growing desire to minimize reflections from ambient lighting and enhance readability in harsh lighting conditions, without the need to increase screen brightness. This demand highlights a significant need for advanced anti-glare (AG) technologies, to increase comfort and eventually reduce energy consumption of the devices. Currently used production technologies are limited in their texture designs, which can lead to suboptimal performance of the anti-glare texture. To overcome this design limitation and improve the performance of the anti-glare feature, this work reports a new, cost-effective, high-volume production method that enables much needed design freedom over a large area. This is achieved by combining mastering via large-area Laser Beam Lithography (LBL) and replication by Nanoimprint Lithography (NIL) processes. The environmental impact of the production method, such as regards material consumption, are considered, and the full cycle from design to final imprint is discussed.

Optical fiber sensors have emerged as a critical sensing technology across various fields due to their advantages, including high potential bandwidth, electrical isolation that is safe for utilization in electrically hazardous environments, high reliability, and ease of maintenance. However, conventional optical fiber sensors face limitations in achieving high sensitivity and precision. The integration of nanostructures with advanced coating technology is one of the critical solutions to enhancing sensor functionality. This review examined nanostructure coating techniques that are compatible with optical fiber sensors and evaluated etching techniques for the improvement of optical fiber sensing technology. Techniques such as vapor deposition, laser deposition, and sputtering to coat the nanostructure of novel materials on the optical fiber sensors are analyzed. The ability of optical fiber sensors to interact with the environment via etching techniques is highlighted by comparing the sensing parameters between etched and bare optical fibers. This comprehensive overview aims to provide a detailed understanding of nanostructure coating and etching for optical fiber sensing and offer insights into the current state and future prospects of optical fiber sensor technology for sensing performance advancement, emphasizing its potential in future sensing applications and research directions.

Initial studies indicate that structured polymer surfaces can support the attachment and biofilm formation of bacteria and thereby provide enhanced positive effects of beneficial bacteria, for instance in biocontrol in aquacultures. In this study, we demonstrate a test platform to further explore the surface topography for bacterial attachment and biofilm growth. It is based on a cyclic olefin copolymer (COC) materials platform, and nanoimprint technology was used for the replication of microstructures. The use of nanoimprint technology ensures precise micropattern transfer, enabling easy prototyping. Further, the process parameters of the mold preparation and nanoimprinting are discussed, with the purpose of optimizing the polymer pattern profile. This study has the potential to identify promising surfaces for biofilm growth of beneficial bacteria.

Electrochemically anodized TiO2 nanotube arrays (NTAs) were used as a support material for the electrodeposition of zinc nanoparticles. The morphology, composition, and crystallinity of the materials were examined using scanning electron microscopy (SEM). Electrochemical impedance spectroscopy (EIS) was performed to evaluate the electrochemical properties of TiO2 NTAs. Annealing post-anodization was shown to be effective in lowering the impedance of the TiO2 NTAs (measured at 1 kHz frequency). Zinc nanohexagons (NHexs) with a mean diameter of ~300 nm and thickness of 10–20 nm were decorated on the surface of TiO2 NTAs (with a pore diameter of ~80 nm and tube length of ~5 µm) via an electrodeposition process using a zinc-containing deep eutectic solvent. EIS and CV tests were performed to evaluate the functionality of zinc-decorated TiO2 NTAs (Zn/TiO2 NTAs) for glucose oxidation applications. The Zn/TiO2 NTA electrocatalysts obtained at 40 °C demonstrated enhanced glucose sensitivity (160.8 μA mM−1 cm−2 and 4.38 μA mM−1 cm−2) over zinc-based electrocatalysts reported previously. The Zn/TiO2 NTA electrocatalysts developed in this work could be considered as a promising biocompatible electrocatalyst material for in vivo glucose oxidation applications.

The demands for high resolution fabrication processes are ever-increasing, with new and optimized methodologies being highly relevant across several scientific fields. We systematically investigated thermal scanning probe lithography process and detailed how tuning temperature and probe contact time on the sample can optimize patterning and achieve 10 nm resolution. Additionally, we propose a novel fabrication methodology that integrates thermal scanning probe lithography and bilayer liftoff, achieving sub-20 nm resolution of the final metallized structures. Each step of the process, from sample preparation to the final liftoff, is described in detail. We also present a quantitative analysis comparing the accuracy of the lithography process to that of the bilayer liftoff. Finally, we show the feasibility of using thermal scanning probe lithography for the fabrication of photonic devices by validating our work with promising dipole geometries for this field.