3D-printed Substrate Research Articles

Lake Shore Restoration with Vallisneria spiralis in Lake Como (Northern Italy) to Improve Sustainability

In the Anthropocene era, lake ecosystems are increasingly subjected to significant human-induced pressures, leading to declines in both biodiversity and habitat quality. However, restoration initiatives offer promising avenues for enhancing the resilience of freshwater environments. This research investigated a range of established and novel methods aimed at promoting the growth of the macrophyte Vallisneria spiralis in the littoral zone of Lake Como, a southern alpine lake in Italy. To conduct this study, samples of Vallisneria spiralis were collected and placed in tanks containing four different types of 3D-printed biodegradable substrates. The optimal conditions for the growth of this species were identified as follows: a temperature range of 25 to 27 °C, the continuous operation of a circulation pump equipped with a filter, the presence of a fertile substrate, and light cycles comprising 6 h of peak illumination followed by 6 h of darkness. Remarkably, the plants exhibited a growth rate of 4 mm per day, increasing from an initial count of 12 specimens to 400 within four months, with a total of over 700 plants by the end of the study. Among the substrates tested, the patch substrate was found to be the most effective. After their introduction into the natural environment, the survival rate of plants established on stable substrates in contact with the lakebed reached an impressive 85.7%. This research represents a pioneering step in demonstrating that Vallisneria spiralis may serve as a viable option for restoration projects in coastal lake habitats, particularly when employing biodegradable substrates.

Photoelectrocatalytic degradation of organophosphate esters using tio2 electrodes produced from 3d-printed ti substrates.

3D printed electrode substrates with novel geometries may significantly improve the efficacy of photoelectrocatalysis for degradation of recalcitrant pollutants such as organophosphate flame retardants (OPFRs). However, the 3D printed substrates often have an irregular topology that can lead to a less uniform arrangement of nanotubes following anodisation. This study investigated the effect of polishing 3D-printed Ti substrates prior to anodisation to form TiO2 nanotube array electrodes, and their subsequent applicability for photoelectrocatalytic treatment of OPFRs in water matrices. Polished and non-polished electrodes exhibited differences in morphology in terms of average roughness, (0.38 and 3.10µm, respectively), leading to more uniform TiO2 nanotubes of the former. Water contact angle measurements revealed the non-polished electrode was super-hydrophilic and the polished electrode hydrophilic (water contact angles of 6.4˚ and 16.1˚, respectively). Despite these differences, the polished and non-polished electrodes exhibited very similar electrochemical responses. In fact, the purity and electrical conductivity of water matrices affected the photoelectrocatalytic performance more than the electrode morphology. The purified water (PW) matrix facilitated the highest degradation/removal of OPFRs, compared to tap water matrices. In particular, individual OPFR degradation levels in PW were 74% ± 9, 37% ± 10, 33% ± 9, 31% ± 11 and 3% ± 5 for triphenyl phosphate, tris(butyl) phosphate, tris(isobutyl) phosphate, tris(2-butoxyethyl) phosphate and tris(2-chloroisopropyl) phosphate, respectively. The removal of OPFRs was relative to their reactivity to hydroxyl radicals, which was higher for the aryl then alkyl straight-chain and then chlorinated compounds. This study reveals that polishing of electrode substrates is not required for the preparation of effective photoelectrocatalytic reactors to treat recalcitrant pollutants (e.g. OPFRs), Importantly, future development of novel high-profile 3D printed electrode will not be hindered by the requirement to polish the substrates prior to anodisation.

Narrowband Frequency-Selective Surface on 3D-Printed Substrate for X-Band Applications

Narrowband Frequency-Selective Surface on 3D-Printed Substrate for X-Band Applications

Leveraging Deep Learning and Generative AI for Predicting Rheological Properties and Material Compositions of 3D Printed Polyacrylamide Hydrogels.

Artificial intelligence (AI) has the ability to predict rheological properties and constituent composition of 3D-printed materials with appropriately trained models. However, these models are not currently available for use. In this work, we trained deep learning (DL) models to (1) predict the rheological properties, such as the storage (G') and loss (G") moduli, of 3D-printed polyacrylamide (PAA) substrates, and (2) predict the composition of materials and associated 3D printing parameters for a desired pair of G' and G". We employed a multilayer perceptron (MLP) and successfully predicted G' and G" from seven gel constituent parameters in a multivariate regression process. We used a grid-search algorithm along with 10-fold cross validation to tune the hyperparameters of the MLP, and found the R2 value to be 0.89. Next, we adopted two generative DL models named variational autoencoder (VAE) and conditional variational autoencoder (CVAE) to learn data patterns and generate constituent compositions. With these generative models, we produced synthetic data with the same statistical distribution as the real data of actual hydrogel fabrication, which was then validated using Student's t-test and an autoencoder (AE) anomaly detector. We found that none of the seven generated gel constituents were significantly different from the real data. Our trained DL models were successful in mapping the input-output relationship for the 3D-printed hydrogel substrates, which can predict multiple variables from a handful of input variables and vice versa.

Facile Synthesis of Soft Core-Shell Nanospheres for Constructing Multiresponsive Photonic Crystal Security Patterns.

Responsive photonic crystals (RPCs) presenting tunable structural colors under external stimuli are widely applied in the fields of dynamic displays, sensors, and anticounterfeiting. However, the development of multiresponsive photonic crystal (MRPC) films possessing versatile variable optical properties remains a significant challenge due to the tedious synthetic procedure of multifunctional building blocks and complex assembly processes, thereby constraining their extensive applications. In the present work, a series of soft nanospheres with a hydrophobic cores and responsive hydrophilic shells have been synthesized by a facile one-step surfactant-free emulsion polymerization method. The MRPC patterns were then prepared by depositing soft nanosphere emulsions onto the 3D-printed substrates with a topological structure followed by drying at room temperature. The shells of soft nanospheres deformed and fused with each other, resulting in the formation of transparent MRPC film patterns. The MRPC patterns exhibited brilliant structural color in a wet state but lost the color again after complete drying. Such a reversible structural color was ascribed to the change of the refractive index (RI) of the hydrophilic shell layers of nanospheres according to wetting/drying state shifting. Moreover, the on-demand designed MRPC patterns could rapidly respond to external stimuli of temperature, pH, and organic solvents in a reversible manner, and multichannel encrypted security labels were also demonstrated. We postulate that our facile and feasible approach can be applied to the systematic design and large-scale production of MRPC patterns for a variety of applications.

Substrate heterogeneities cause root growth trajectories to switch from vertical to oblique.

Hard pans, soil compaction, soil aggregation and stones create physical barriers that can affect the development of a root system. Roots are known to exploit paths of least resistance to avoid such obstacles, but the mechanism through which this is achieved is not well understood. Here, we combined 3D-printed substrates with a high-throughput live imaging platform to study the responses of plant roots to a range of physical barriers. Using image analysis algorithms, we determined the properties of growth trajectories and identified how the presence of rigid circular obstacles affects the ability of a primary root to maintain its vertical trajectory. Results showed the types of growth responses were limited, both vertical and oblique trajectories were found to be stable and influenced by the size of the obstacles. When obstacles were of intermediate sizes, trajectories were unstable and changed in nature through time. We formalised the conditions for root trajectory to change from vertical to oblique, linking the angle at which the root detaches from the obstacle to the root curvature due to gravitropism. Exploitation of paths of least resistance by a root may therefore be constrained by the ability of the root to curve and respond to gravitropic signals.

Three-Dimensionally Printed Microsystems to Facilitate Flow-Based Study of Cells from Neurovascular Barriers of the Retina.

Rapid prototyping has produced accessible manufacturing methods that offer faster and more cost-effective ways to develop microscale systems for cellular testing. Commercial 3D printers are now increasingly adapted for soft lithography, where elastomers are used in tandem with 3D-printed substrates to produce in vitro cell assays. Newfound abilities to prototype cellular systems have begun to expand fundamental bioengineering research in the visual system to complement tissue engineering studies reliant upon complex microtechnology. This project used 3D printing to develop elastomeric devices that examined the responses of retinal cells to flow. Our experiments fabricated molds for elastomers using metal milling, resin stereolithography, and fused deposition modeling via plastic 3D printing. The systems were connected to flow pumps to simulate different flow conditions and examined phenotypic responses of endothelial and neural cells significant to neurovascular barriers of the retina. The results indicated that microdevices produced using 3D-printed methods demonstrated differences in cell survival and morphology in response to external flow that are significant to barrier tissue function. Modern 3D printing technology shows great potential for the rapid production and testing of retinal cell responses that will contribute to both our understanding of fundamental cell response and the development of new therapies. Future studies will incorporate varied flow stimuli as well as different extracellular matrices and expanded subsets of retinal cells.

CO2 Capture with Polyethylenimine Supported on 3D-Printed Porous SiO2 Structures.

Amines supported on porous solid materials have a high CO2 adsorption capacity and low regeneration temperature. However, the high amine load on such substrates and the substrate itself may lead to substantial pressure drop across the reactor. Herein, we compare the CO2 adsorption capacity and pressure drop of fumed silica powder to 3D-printed monolithic fumed silica structures, both functionalized by polyethylenimine (PEI), and find a drastically reduced pressure drop for 3D-printed substrates (0.01 bar vs. 0.76 bar) in the sorption bed with equal CO2 adsorption capacity. Furthermore, the effect of 3D-printing nozzle diameter and PEI loading on the adsorption capacity are investigated and the highest capacities (2.0 mmol/g at 25 °C with 5000 ppm CO2) are achieved with 0.4 mm nozzle size and 34 wt% PEI loading. These high capacities are achieved since the 3D printing and subsequent sintering (700 °C) of monolithic samples does not compromise the surface area of the fumed silica. Finally, the comparison between 3D-printed monoliths and extruded granulate of varying diameter reveals that the ordered channel system of 3D-printed structures is superior to randomly oriented granulate in terms of CO2 adsorption capacity.

2D/2D homojunction-mediated charge separation: Synergistic effect of crystalline C3N5 and g-C3N4 via electrostatic self-assembly for photocatalytic hydrogen and benzaldehyde production

Homojunction engineering is a promising modification strategy to improve charge carrier separation and photocatalytic performance of carbon nitrides. Leveraging intrinsic heptazine/triazine phase and face-to-face contact, crystalline C3N5 (CC3N5) was combined with protonated g-C3N4 (pgCN) through electrostatic self-assembly to achieve robust 2D/2D homojunction interfaces. The highest photocatalytic performance was obtained through crystallinity and homojunction engineering, by controlling the pgCN:CC3N5 ratio. The 25:100 pgCN:CC3N5 homojunction (25CgCN) had the highest hydrogen production (1409.51 μmol h−1) and apparent quantum efficiency (25.04%, 420 nm), 8-fold and 180-fold higher than CC3N5 and pgCN, respectively. This photocatalytic homojunction improves benzaldehyde and hydrogen production activity, retaining 89% performance after 3 cycles (12 h) on a 3D-printed substrate. Electron paramagnetic resonance demonstrated higher ·OH−, ·O2− and hole production of irradiated 25CgCN, attributed to crystallinity and homojunction interaction. Thus, electrostatic self-assembly to couple CC3N5 and pgCN in a 2D/2D homojunction interface ameliorates the performance of multifunctional solar-driven applications.

Bulge-Free and Homogeneous Metal Line Jet Printing with StarJet Technology.

The technology to jet print metal lines with precise shape fidelity on diverse substrates is gaining higher interest across multiple research fields. It finds applications in additively manufactured flexible electronics, environmentally friendly and sustainable electronics, sensor devices for medical applications, and fabricating electrodes for solar cells. This paper provides an experimental investigation to deepen insights into the non-contact printing of solder lines using StarJet technology, eliminating the need for surface activation, substrate heating, curing, or post-processing. Moreover, it employs bulk metal instead of conventional inks or pastes, leading to cost-effective production and enhanced conductivity. The effect of molten metal temperature, substrate temperature, standoff distance, and printing velocity was investigated on polymer foils (i.e., PET sheets). Robust printing parameters were derived to print uniform, bulge-free, bulk metal lines suitable for additive manufacturing applications. The applicability of the derived parameters was extended to 3D-printed PLA, TPU, PA-GF, and PETG substrates having a much higher surface roughness. Additionally, a high aspect ratio of approx. 16:1 wall structure has been demonstrated by printing multiple metal lines on top of each other. While challenges persist, this study contributes to advancing additively manufactured electronic devices, highlighting the capabilities of StarJet metal jet-printing technology.

Field Emission from Carbon Nanotubes on Titanium Nitride-Coated Planar and 3D-Printed Substrates.

Carbon nanotubes (CNTs) are well known for their outstanding field emission (FE) performance, facilitated by their unique combination of electrical, mechanical, and thermal properties. However, if the substrate of choice is a poor conductor, the electron supply towards the CNTs can be limited, restricting the FE current. Furthermore, ineffective heat dissipation can lead to emitter-substrate bond degradation, shortening the field emitters' lifetime. Herein, temperature-stable titanium nitride (TiN) was deposited by plasma-enhanced atomic layer deposition (PEALD) on different substrate types prior to the CNT growth. A turn-on field reduction of up to 59% was found for the emitters that were generated on TiN-coated bulk substrates instead of on pristine ones. This observation was attributed exclusively to the TiN layer as no significant change in the emitter morphology could be identified. The fabrication route and, consequently, improved FE properties were transferred from bulk substrates to free-standing, electrically insulating nanomembranes. Moreover, 3D-printed, polymeric microstructures were overcoated by atomic layer deposition (ALD) employing its high conformality. The results of our approach by combining ALD with CNT growth could assist the future fabrication of highly efficient field emitters on 3D scaffold structures regardless of the substrate material.

3D printing encouraging desired in-situ polypyrrole seed-polymerization for ultra-high energy density supercapacitors

The tireless pursuit of supercapacitors with high energy density entails the parallel advancement of well-suited electrode materials and elaborately engineered architectures. Polypyrrole (PPy) emerges as an exceedingly conductive polymer and a prospective pseudocapacitive materials for supercapacitors, yet the inferior cyclic stability and unpredictable polymerization patterns severely impede its real-world applicability. Here, for the first time, an innovative seed-induced in-situ polymerization assisted 3D printing strategy is proposed to fabricate PPy-reduced graphene oxide/poly (vinylidene difluoride-co-hexafluoropropylene) (PVDF-HFP) (PPy-rGO/PH) electrodes with controllable polymerization behavior and exceptional areal mass loading. The preferred active sites uniformly pre-planted on the 3D-printed graphene substrates serve as reliable seeds to induce efficient polypyrrole deposition, achieving an impressive mass loading of 185.6 mg cm−2 (particularly 79.2 mg cm−2 for polypyrrole) and a superior areal capacitance of 25.2 F cm−2 at 2 mA cm−2 for a 12-layer electrode. In agreement with theses appealing features, an unprecedented areal energy density of 1.47 mW h cm−2 for a symmetrical device is registered, a rarely achieved value for other PPy/rGO-based supercapacitors. This work highlights a promising route to preparing high energy density energy storage modules for real-world applications.

Innovative syntheses of immobilized CuxO semiconductors grown on 3D prints and their photoelectrochemical activity for sulfamethoxazole degradation

Traditional copper oxide manufacturing processes require high energy consumption, high synthesis temperatures, and long process times. This study proposes an innovative additive manufacturing process to support immobilized copper oxide, offering greater design flexibility and customization. CuxO semiconductors were synthesized on 3D-printed substrates via the anodization process and evaluated for their effectiveness in degrading sulfamethoxazole (SMX). XRD analysis of the samples revealed the presence of both CuO and Cu2O crystalline phases, this mixture of oxides helps to expand the absorption range of visible light. The immobilized CuxO semiconductors exhibited band gaps ranging between 1.6 and 1.8 eV. Negative current densities and Mott-Schottky analysis confirmed the nature of the p-type semiconductor. Semiconductors grown by 3D printing demonstrated remarkable degradation capacity for the antibiotic sulfamethoxazole (SMX), achieving 60% degradation after 360 minutes under visible light. Kinetic degradation tends to be a first-order and zero-order model. TOC analysis further revealed the formation of reaction intermediates during SMX degradation, ultimately leading to the mineralization of the contaminant. Based on these results, we report, for the first time CuxO semiconductors grown on large 3D-printed substrates as promising photocatalysts for the degradation of emerging water pollutants. Based on these results, we report, for the first time, that CuxO semiconductors grown on large 3D-printed substrates are promising photocatalysts for the degradation of emerging water contaminants. Furthermore, it should be emphasized that the proposed method is faster and does not require subsequent thermal treatments for its functionalization, making it attractive for various industrial applications.

3D-printed Al2O3 framework supported carbon-bridged tri-s-triazine of g-C3N4 for photocatalytic tetracycline oxidation

Powder-like g-C3N4 has been widely used as a photocatalyst but exhibits several drawbacks, including unrecyclable, high charge recombination, and limited light absorption. In this study, carbon-bridged g-C3N4 was successfully prepared and coated on a 3D-printed Al2O3 substrate for the photocatalytic oxidation of tetracycline. Oxamide (OD), malonamide (MD), and succinamide (SD) were used as carbon-containing linkers to react with precursors (melamine and urea) and produce carbon-bridged g-C3N4. Carbon substitution at the bridged N atoms of g-C3N4 improved light absorption, reduced charge recombination, and resulted in high photocatalytic tetracycline removal efficiency. Computational calculations were also employed, and Bader charge analysis supported the charge redistribution and charge transfer of the carbon-bridged g-C3N4 samples. Our results indicated that the degradation of tetracycline followed step-by-step oxidation, deamination, and mineralization to form CO2 and H2O. The 3D-printed Al2O3-supported carbon-bridged g-C3N4 exhibited a high removal rate of 85–90 % and stability for photocatalytic reactions and can be reused for at least 10 cycles. This study demonstrates that the 3D-printed Al2O3-supported carbon-bridged g-C3N4 catalyst is an efficient and effective catalyst support system for photocatalytic reactions.

Isotype heterojunction: tuning the heptazine/triazine phase of crystalline nitrogen-rich C3N5 towards multifunctional photocatalytic applications.

Photocatalytic technology has been well studied as a means to achieve sustainable energy generation through water splitting or chemical synthesis. Recently, a low C/N atomic ratio carbon nitride allotrope, C3N5, has been found to be highly prospective due to its excellent electronic properties and ample N-active sites compared to g-C3N4. Tangentially, crystalline g-C3N4 has also been a prospective candidate due to its improved electron transport and extended π-conjugated system. For the first time, our group successfully employed a one-step molten salt calcination method to prepare novel N-rich crystalline C3N5 and elucidate the effect of calcination temperature on the heptazine/triazine phase. Calcination temperatures of 500 °C (CC3N5-500) and 550 °C (CC3N5-550) lead to crystalline carbon nitride with both heptazine and triazine phases, forming an intimate isotype heterojunction for robust interfacial charge separation. An excellent photocatalytic hydrogen evolution rate (359.97 μmol h-1; apparent quantum efficiency (AQE): 12.86% at 420 nm) was achieved using CC3N5-500, which was 15-fold higher than that of pristine C3N5. Furthermore, CC3N5-500 exhibited improved activity for simultaneous benzyl alcohol oxidation and hydrogen production, as well as H2O2 production (AQE: 9.49% at 420 nm), signifying its multitudinous photoredox capabilities. Moreover, the recyclability tests of the optimal CC3N5-500 on a 3D-printed substrate also showed a 92% performance retention after 4 cycles (16 h). This highlights that crystalline C3N5 significantly augmented the reaction performance for diverse multifunctional solar-driven applications. As such, these results serve as a guide toward the structural tuning of 2D metal-free carbon nanomaterials with tunable crystallinity toward achieving boosted photocatalysis.

Immobilizing nanozymes on 3D-printed metal substrates for enhanced peroxidase-like activity and trace-level glucose detection.

The prevalence of 3D-printed portable biomedical sensing devices, which are fashioned mainly from plastic and polymer materials, introduces a pressing concern due to their limited reusability and consequential generation of substantial disposable waste. Considering this, herein, we pioneered a ground-breaking advancement, i.e., a 3D-printed metal substrate-based enzyme. Our inventive methodology involved the synthesis of a thermally degraded Fe-based metal-organic framework, DEG 500, followed by its deposition on a 3D-printed metal substrate composed of Ti-Al-V alloy. This novel composite exhibited remarkable peroxidase-like activity in a range of different temperatures and pH, coupled with the ability to detect glucose in real-world samples such as blood and fruit juices. The exceptional enzymatic behaviour was attributed to the diverse iron (Fe) oxidation states and the presence of oxygen vacancies, as evidenced through advanced characterization techniques. Fundamentally, we rigorously explored the mechanistic pathway through controlled studies and theoretical calculations, culminating in a transformative stride toward more sustainable and effective biomedical sensing practices.

Multipotent Mesenchymal Cells Homing and Differentiation on Poly(ε-caprolactone) Blended with 20% Tricalcium Phosphate and Polylactic Acid Incorporating 10% Hydroxyapatite 3D-Printed Scaffolds via a Commercial Fused Deposition Modeling 3D Device.

As highlighted by the 'Global Burden of Disease Study 2019' conducted by the World Health Organization, ensuring fair access to medical care through affordable and targeted treatments remains crucial for an ethical global healthcare system. Given the escalating demand for advanced and urgently needed solutions in regenerative bone procedures, the critical role of biopolymers emerges as a paramount necessity, offering a groundbreaking avenue to address pressing medical needs and revolutionize the landscape of bone regeneration therapies. Polymers emerge as excellent solutions due to their versatility, making them reliable materials for 3D printing. The development and widespread adoption of this technology would impact production costs and enhance access to related healthcare services. For instance, in dentistry, the use of commercial polymers blended with β-tricalcium phosphate (TCP) is driven by the need to print a standardized product with osteoconductive features. However, modernization is required to bridge the gap between biomaterial innovation and the ability to print them through commercial printing devices. Here we showed, for the first time, the metabolic behavior and the lineage commitment of bone marrow-derived multipotent mesenchymal cells (MSCs) on the 3D-printed substrates poly(e-caprolactone) combined with 20% tricalcium phosphate (PCL + 20% β-TCP) and L-polylactic acid (PLLA) combined with 10% hydroxyapatite (PLLA + 10% HA). Although there are limitations in printing additive-enriched polymers with a predictable and short half-life, the tested 3D-printed biomaterials were highly efficient in supporting osteoinductivity. Indeed, considering different temporal sequences, both 3D-printed biomaterials resulted as optimal scaffolds for MSCs' commitment toward mature bone cells. Of interest, PLLA + 10% HA substrates hold the confirmation as the finest material for osteoinduction of MSCs.

Mold-Free Manufacturing of Highly Sensitive And Fast Response Pressure Sensors Through High-Resolution 3d Printing And Conformal Oxidative Chemical Vapor Deposition Polymers.

In this work, w e showcase a new manufacturing paradigm to exclude conventional mold-dependent manufacturing of pressure sensors, which typically requires a series of complex and expensive patterning processes. Our mold-free manufacturing leverages high-resolution 3D printed multiscale microstructures as substrate and a gas-phase conformal polymer coating technique to complete the mold-free sensing platform. The array of dome and spike structures with a controlled spike density of a 3D-printed substrate ensures a large contact surface with pressures applied and extended linearity in a wider pressure range. For uniform coating of sensing elements on the microstructured surface, oxidative chemical vapor deposition is employed to deposit a highly conformal and conductive sensing element, poly(3,4-ethylenedioxythiophene) at low temperatures (< 60 °C). The fabricated pressure sensor reacts sensitively to various ranges of pressures (up to 185 kPa-1 ) depending on the density of the multiscale features and shows an ultra-fast response time (∼36 μs). The mechanism investigations through the finite element analysis identify the effect of the multiscale structure on the figure-of-merit sensing performance. Our unique findings are expected to be of significant relevance to the technology that requires higher sensing capability, scalability, and facile adjustment of a sensor geometry in a cost-effective manufacturing manner. This article is protected by copyright. All rights reserved.

Failure and fracture in adhesively bonded 3D-printed joints: An overview on the current trends

Additive manufacturing (AM) as an innovative technique with favourable and unique solutions in fabricating complex products, is being widely used in diverse applications. AM, also known as three-dimensional (3D) printing technology was introduced for fabrication of prototypes, and currently its applications have been widely extended to production of end-used products too. As a result, mechanical strength of 3D-printed parts, and specially joints with 3D-printed substrates (adherends) gain considerable significance. This review attempts to comprehensively summarise recent advancements in failure and fracture of adhesively bonded joints with 3D-printed polymeric adherends. To this aim, we have reviewed experimental studies, which investigate effects of adhesive and printing parameters on the failure of 3D-printed adhesive joints. In addition, different approaches to strength improvement of 3D-printed adhesive joints are reviewed and discussed. Since computational finite element models (FEM) can provide a profound knowledge about the stress and force transition between adhesive layers and 3D-printed adherends, an overview on different FEM approaches in the field has been presented. The documented data can be used not only for comparison, failure analysis, and improvement of 3D-printed adhesive joints, but also is beneficial for the future research and further studies in fabrication of a 3D-printed joint with a superior structural performance and integrity.

A High Gain Multi-Port Series Fed Array Realized with Micromachined Low-Cost 3D-Printed Substrate

A low-cost three-port series-fed antenna array with pattern diversity for WLAN applications is presented. The three antennas resonate at 5.8 GHz with 12 dBi antenna gain. The antenna substrate consists of an air cavity within the substrate, which is introduced to enhance the gain and radiation efficiency. The principle of micromachining was used to realize the substrate characteristic that lowers the dielectric constant, compared to a conventional non-micromachined substrate. The antenna uses scaled parasitic patches as a superstrate to improve and equalize the gain of the respective antennas when the antenna beam scans through +180, 00, and −180. The parasitic patches as a superstrate were found to have low scanning loss when the antenna beam is tilted from the broadside. The proposed superstrate design enhances the gain at the broadside and oblique radiations making the design more versatile as the gain enhancement becomes invariant to the incidence angle. The planar superstrate enhances the gains of three antennas with 2.4, 2.8, and 7.1 dB so that the final antenna gain is equalized to 12 dBi at the three ports. To validate the design, the antenna module is fabricated on the polylactic acid (PLA) substrate using the industry-standard photolithography process.