Direct Printing Research Articles

Substrate-Free Transfer of Silicon- and Metallic-Based Strain Sensors on Textile and in Composite Material for Structural Health Monitoring.

New technologies to integrate electronics and sensors on or into objects can support the growth of embedded electronics. The method proposed in this paper has the huge advantage of being substrate-free and applicable to a wide range of target materials such as fiber-based composites, widely used in manufacturing, and for which monitoring applications such as fatigue, cracks, and deformation detection are crucial. Here, sensors are first fabricated on a donor substrate using standard microelectronic processes and then transferred to the host material by direct transfer printing. Results show the viability of composites instrumented by strain gauges. Indeed, dynamic and static measurements highlight that the deformations can be detected with high sensitivity both on the surface and at various points in the depth of the composite material. Thanks to this technology, for the first time, a substrate-free piezoresistive n-doped silicon strain sensor is transferred into a composite material and characterized as a function of strain applied on it. It is shown that the transfer process does not alter the electrical behavior of the sensors that are five times more sensitive than extensively used metallic ones. An application designed for monitoring the deformation of a rudder foil with a classic NACA profile in real time is presented.

Unraveling the main issues of direct sample printing and sample cutting from a sheet of tensile test samples for characterization of Material Extrusion components

AbstractThis research investigates the influence of varied sample manufacturing strategies on the mechanical properties of Material Extrusion (MatExt) Additive Manufacturing components. Two procedures were investigated: direct sample printing and sample cutting from a sheet. The thickness of the samples was also varied to determine possible differences in the measurements performed. Through a comprehensive analysis involving mechanical testing, optical microscopy, and IR thermography during deposition, the study revealed significant implications of the manufacturing strategy on the thermal history and polymer chain entanglement. The results indicated that Young’s modulus and the tensile strength produced through direct printing differed from that measured on the samples made through sample cutting. At the same time, the elongation at rupture was less influenced by the manufacturing strategy. The sample thickness also influenced the fracture strength; the thicker samples were characterized by a strength of 27.9 MPa, which was higher by 23% than that of the extracted samples.The observed differences in mechanical behavior underscore the critical role of sample manufacturing strategy in determining the final mechanical properties of upright samples. Results shed light on the complex interplay between manufacturing protocols and component performance in MatExt applications.

Drop-on-Demand Pyro-Electrohydrodynamic Printing of Nematic Liquid Crystal Microlenses.

Inkjet printing of liquid crystal (LC) microlens arrays is particularly appealing for the development of switchable 2D/3D organic light-emitting diode (OLED) displays, as the printing process ensures that the lenses can be deposited directly and on-demand onto the pixelated OLED layer without the need for additional steps, thus simplifying fabrication complexity. Even if different fabrication technologies have been employed and good results in LC direct printing have already been achieved, all the systems used require costly equipment and heated nozzles to reduce the LC solution's viscosity. Here, we present the direct printing of a nematic LC (NLC) lens by a Drop-on-Demand (DoD) inkjet printing by a pyro-electrohydrodynamic effect for the first time. The method works at ambient temperature and avoids dispensing nozzles, thus offering a noncontact manipulation approach of liquid with high resolution and good repeatability on different kinds of substrates. NLC microlenses are printed on different substrates and fully characterized. Polarization properties are evaluated for various samples, i.e., NLC lenses on unaligned and indium-tin oxide (ITO) aligned. Moreover, an in-depth characterization of the NLC lenses is reported by polarized optical microscopy and by analyzing the birefringence in digital holographic microscopy.

Fabrication of micro-ultrasonic phased array electrode via electric field-driven printing method

The electrode is an important part of a micro-ultrasonic phased array, commonly fabricated by magnetron sputtering technology. However, with the expansion of the application field, the structures of the phased arrays are becoming more complex, making the traditional magnetron sputtering method no longer applicable, and the realization of micro-scale phased array electrodes by direct printing technology still faces great challenges. Herein, an electric field-driven direct printing method was proposed to fabricate micro-ultrasonic phased array electrodes. The influence of sintering parameters on the resistivity and the effect of printing parameters on the geometric size and surface morphology of the electrode were comprehensively explored, and the mathematical model between the electrode line width and the printing parameters was established. The final printed electrodes exhibit superior properties with a resistivity of 2.4 × 10−7 Ω⋅m , a surface roughness range of 460–550 nm, and a line width range of 125–480 µm. Additionally, a micro-scale electrode was printed on the piezoelectric ceramic with PZT-5 as the material, and after polarization treatment, the piezoelectric coefficient can reach 405 pC N−1, which proves that this method can be applied in the field of fabricating phased array electrodes.

Facile Fabrication of Flexible and High‐Performing Thermoelectrics by Direct Laser Printing on Plastic Foil (Adv. Mater. 15/2024)

Facile Fabrication of Flexible and High‐Performing Thermoelectrics by Direct Laser Printing on Plastic Foil (Adv. Mater. 15/2024)

On-chip fabrication and in-flow 3D-printing of microgel constructs: from chip to scaffold materials in one integral process

Bioprinting has evolved into a thriving technology for the fabrication of cell-laden scaffolds. Bioinks are the most critical component for bioprinting. Recently, microgels have been introduced as a very promising bioink, enabling cell protection and the control of the cellular microenvironment. However, the fabrication of the bioinks involves the microfluidic production of the microgels, with a subsequent multistep process to obtain the bioink, which so far has limited its application potential. Here we introduce a direct coupling of microfluidics and 3D-printing for the continuous microfluidic production of microgels with direct in-flow printing into stable scaffolds. The 3D-channel design of the microfluidic chip provides access to different hydrodynamic microdroplet formation regimes to cover a broad range of droplet and microgel diameters. After exiting a microtubing the produced microgels are hydrodynamically jammed into thin microgel filaments for direct 3D-printing into two- and three-dimensional scaffolds. The methodology enables the continuous on-chip encapsulation of cells into monodisperse microdroplets with subsequent in-flow cross-linking to produce cell-laden microgels. The method is demonstrated for different cross-linking methods and cell lines. This advancement will enable a direct coupling of microfluidics and 3D-bioprinting for scaffold fabrication.

Direct sound printing: Way of manipulating ultrasonic chemistry to print directly engineering structures and remotely inside body

Direct sound printing (DSP) is a new class of additive manufacturing processes developed in our lab, in which chemical reactions during the 3D printing process are driven by sonochemical route using cavitation bubbles induced by focused ultrasound waves. This invited paper will present methods and possibilities of printing engineering structures with DSP. In addition, this talk will cover a new area called remote distance printing (RDP) and consequent applications. RDP is a new realm introduced by DSP method in which the printing location is not accessible by common energy sources like light or heat. In this situation, ultrasound could penetrate optically opaque materials and conduct printing without direct access to the printing location. This concept opens a wide variety of applications in engineering or medical fields. The focus of this paper is the application of DSP-RDP in biomedical application to print objects inside body without open surgery in a non-invasive manner. Ultrasound penetrates skin and tissues in DSP and is focused on the printing location inside body where the printing material is injected. This work explains DSP in detail and the interaction of the sound with the printing material and how the material is transformed from liquid to solid. The process is demonstrated using a test study conducted using tissue phantoms and also real porcine tissue. This work opens new applications to 3D print with ultrasound where no other 3D printing approaches can achieve.

Direct printing of conductive hydrogels using two-photon polymerization

Poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) based conductive hydrogels have been extensively used for bioelectronics and tissue engineering applications owing to their high electrical conductivity and ability to interface with soft biological tissues. However, the fabrication of PEDOT:PSS-based hydrogels has mostly relied on conventional fabrication techniques such as casting and transfer printing, which limits the feature size to micro- or mesoscale. To address these limitations, this study offers a novel PEDOT:PSS-based hydrogel material that can be printed directly to nano/microscale structures using the Two-Photon Polymerization (TPP) technique. The TPP-printability of the newly developed hydrogel was analyzed, and its printing window was characterized. The prepared hydrogel exhibits enhanced radial swelling, electrical properties, and biocompatibility compared to the pristine PEDOT:PSS. To validate the micro-manufacturing feasibility of hydrogel, several microstructures were fabricated using the TPP process. The fabricated microstructures demonstrate many properties, including electrical conductivity, biocompatibility, high resolution, and structural stability. The direct printing of highly conductive PEDOT:PSS hydrogel micro-devices overcomes the limitations of traditional conductive hydrogel manufacturing methods. It opens up new possibilities for applications in micro-energy storage devices, flexible micro/nanoelectromechanical systems (MEMS), and flexible biomedical micro-devices. The combination of high-resolution direct printing and unique hydrogel properties offers promising opportunities in these fields.

High-Precision Printing of Flexible MXene Patterns for Dynamically Tunable Electromagnetic Interference Shielding Performance.

Smart electromagnetic interference (EMI) shielding materials are of great significance in coping with the dynamic performance demands of cutting-edge electronic devices. However, smart EMI shielding materials are still in their infancy and face a variety of challenges (e.g., large thickness, limited tunable range, poor reversibility, and unclear mechanisms). Here, we report a method for controllable shielding electromagnetic (EM) waves through subwavelength structure changes regulated by the customized structure via a direct printing route. The highly conductive MXene ink is regulated with metal ions (Al3+ ions), giving superb metallic conductivity (∼5000 S cm-1) for the printed lines without an annealing treatment. The reversible tunability of EMI shielding effectiveness (SE) ranging from 8.2 dB ("off" state) to 34 dB ("on" state) is realized through the controllable modulation of subwavelength structure driven by stress. This work provides a feasible strategy to develop intelligent shielding materials and EM devices.

Influence of LLDPE on the mechanical properties improvement of 3D printed POE/LLDPE blends

AbstractPolyolefins and polyolefin elastomers (POEs) are widely used in various applications due to their unique properties. However, their use in 3D printing has been limited due to challenges such as excessive softness, shrinkage, warpage, and poor mechanical properties. In this study, two strategies were employed to enhance the performance of POEs in 3D printing. First, POE was blended with 10%, 30%, and 50% percentages of linear low‐density polyethylene (LLDPE) to improve the material's mechanical properties and printability. Second, a specialized printer called a pneumatic feeding fused granule fabrication (FGF) printer was used. This printer allows for the direct printing of material granules, eliminating the need for filaments and resolving filament‐related problems. To evaluate the quality of the printed parts, tensile tests, dynamic mechanical thermal analysis (DMTA), and scanning electron microscopy (SEM) imaging were conducted. The printed parts showed desirable tensile properties (with approximately 3000% elongation at break and approximately 12 MPa tensile strength). Compression tests were also conducted on cubic structures with varied composition ratios and printing patterns such as grid, triangle, and honeycomb. The main purpose of this research was to explore the energy absorption capabilities of the printed blends. The results of our study showed that blending POE with LLDPE improved printability, tensile strength, energy absorption, and compressive properties. The blend with 50% LLDPE and honeycomb structure exhibited the best compressive and energy absorption properties.Highlights Blending of POE and LLDPE using melt mixing with three different blending ratios. Successful 3D printing with the fused granule fabrication technique. Investigating mechanical properties, microstructure, and thermal analysis. 125% increase in ultimate tensile strength by increasing LLDPE. Achieving the highest energy absorption for the 3D printed honeycomb structure.

Evolution and Innovations in Pattern Making Techniques for Enhanced Garment Construction: A Comprehensive Review

Pattern-making has evolved significantly over time, combining traditional craftsmanship with technological advancements like computer-aided design software and 3D modelling. This has increased accuracy, efficiency, and productivity in garment design, allowing for greater creativity and customization. Sustainability principles have become a priority in the fashion industry, with designers using zero-waste design approaches to minimize textile waste. Digital tools have revolutionized traditional pattern-making practices, facilitating collaboration between designers and manufacturers, enhancing accuracy and precision. Virtual and augmented reality have added a new dimension to pattern-making and garment construction, allowing designers to visualize and experience their designs in a virtual environment before translating them into physical garments. Technological innovations have also led to advancements in materials and manufacturing processes, offering designers more options for innovative and eco-friendly designs. The integration of 3D printing into modern garment construction has revolutionized the fashion industry by offering designers new possibilities for creativity and efficiency. Future trends in pattern-making include virtual and augmented reality technologies for virtual fitting rooms and advances in 3D printing technology for direct garment printing.

Investigating the Impact of Productivity on Surface Roughness and Dimensional Accuracy in FDM 3D Printing

Over the past three decades, 3D printing technologies have undergone significant advancements, revolutionizing various industries, such as automotive. Additive manufacturing has played a crucial role in reducing product development time and enabling the direct printing of functional parts. One of the key advantages of additive manufacturing is its ability to provide greater design freedom compared to traditional manufacturing methods. This means that complex geometries and varying material properties can be easily printed. In this research paper, the author focused on investigating the impact of layer thickness and part orientation on the surface roughness and accuracy of printed parts. The main objective was to identify the optimal combination of layer thickness and part orientation that would yield the best results in terms of surface roughness and accuracy, considering printing time as a variable. The results from printing time, accuracy and surface roughness measurements showed that the vertical orientation is the superior for cylindrical orientation.

Ethanol-induced gelation enables direct three-dimensional printing of sodium alginate hydrogel

Hydrogels have found wide applications in various fields, but further advances in hydrogel-based applications hinge upon overcoming the challenge of generating complex structures. Although three-dimensional (3D) printing enables customized designs, it remains challenging to print hydrogel structures directly without using supporting materials or incorporating polymeric or solid thickeners due to the low printability of hydrogel precursor solutions. Here, we demonstrate that direct 3D printing of sodium alginate (SA) hydrogel structures can be achieved by introducing ethanol into the SA solution. On the one hand, ethanol enables a sol-to-gel transition to occur by lowering the temperature. Our molecular dynamics (MD) simulations reveal that the gelation occurs due to disrupted hydrogen bonding interaction among SA chains and water. On the other hand, the presence of ethanol notably increases the viscosity, yield stress, and shear-thinning feature of SA solution, making it an ideal 3D printing ink. An isotropic shrinkage of the printed structures is observed after further gelation with Ca2+ ions and the removal of ethanol. Our study provides an effective approach for direct printing of SA hydrogels with enhanced printing resolution (>10 %), paving the way for more advanced hydrogel-based applications in various fields.

Dry‐Wet Hybrid Direct Printing of Laser‐Induced Graphene and Zinc Oxide Nanoribbons for Continuous‐Flow Manufacturing of Flexible Wearable Photodetectors

AbstractFlexible wearable electronics enable an in situ and real‐time measurement of human physiology and micro‐environment. Although large‐scale production of flexible wearable electronics is demonstrated using direct printing techniques, the “wet” nature of these techniques requires multiple procedures and chemicals to prepare printable inks, increasing the complexity and cost. Here, a dry‐wet hybrid direct printing is developed for the mass production of flexible wearable photodetectors, in which a “dry” direct laser writing and a “wet” screen printing are employed to fabricate laser‐induced graphene as electrode layer and zinc oxide as photosensitive layer, respectively. The liquid‐free fabrication of LIG significantly reduces the complexity and cost of the production. An automatic conveyor belt is designed to realize continuous‐flow manufacturing. The photodetectors demonstrate good ultraviolet (UV) photodetection performances, such as a photo‐to‐dark current ratio (Iphoto/Idark) of 5.67 × 105, approaching the record of similar devices. The manufacturing system presents a high reproducibility, considering that Iphoto/Idark only fluctuates within 7.10%. The flexible photodetectors are worn as wristbands after being integrated with a data acquisition and transmission circuit. UV intensity is real‐time monitored on a self‐developed mobile application. The continuous‐flow manufacturing based on the developed dry‐wet hybrid direct printing sheds light on the mass production of flexible wearable electronics.

Additive manufacturing of interconnected hierarchically porous zirconia: Utilizing both microspherical and filamentary pore-forming agents via direct ink printing

Osteogenic differentiation and bone regeneration can be effectively aided by porous scaffolds with multiscale cellular structures, making it easier to repair defects in bone tissue. Due to the scarcity of pore-forming agents, it is extremely challenging to fabricate interconnected hierarchically porous zirconia at multi-scale. This work described a novel and straightforward method for directly imprinting a slurry containing two pore-forming agents (microspherical and filamentary) to produce strong and highly porous zirconia (ZrO2) ceramics with four levels of porosity ranging from nanometers to millimeters. The concentration of hemp fibers significantly affected printability when the rheological behavior of a zirconia slurry was examined. Utilizing a scanning electron microscope (SEM) to monitor the development of powder interstices under various sintering techniques. The permeability performance was assessed when simulated plasma had fully filled the scaffolds. The structure had a high compressive strength of 24.18 MPa, a porosity of 80.9 %, an apparent porosity of 55.7 %, and took just 1.11 s to fill a scaffold that was 15 mm high. It is anticipated that the proposed route will be expanded to include various engineering materials for structural and practical applications.

Evaluation on Surface Characteristics, Accuracy, and Dimensional Stability of Tooth Preparation Dies Fabricated by Conventional Gypsum and 3D-Printed Workflows.

To evaluate the surface characteristics, accuracy (trueness and precision), and dimensional stability of tooth preparation dies fabricated using conventional gypsum and direct light processing (DLP), stereolithography (SLA), and polymer jetting printing (PJP) techniques. Gypsum preparation dies were replicated according to the reference data and imported into DLP, SLA, and PJP printers, and the test data were obtained by scanning after 0, 1, 3, 7, 14, 28, and 42 days. After analyzing the surface characteristics, a best-fit algorithm between the test and the reference data was used to evaluate the accuracy and dimensional stability of the preparation dies. The data were analyzed by one-way analysis of variance and Tukey test or Kruskal-Wallis H test (α = .05). Compared with the gypsum group (3.61 ± 0.59 μm), the root mean square error (RMSE) values of the SLA group (5.33 ± 0.48 μm) was rougher (P < .05), the PJP group (2.43 ± 0.37 μm) was smoother (P < .05), and the DLP group (2.92 ± 0.91 μm) had no significant difference (P > .05). For trueness, the RMSE was greater in the PJP (34.90 ± 4.91 μm) and SLA (19.01 ± 0.95 μm) groups than in the gypsum (16.47 ± 0.47 μm) group (P < .05), and no significant difference was found between the DLP (17.10 Å} 1.77 μm) and gypsum groups. Regarding precision, the RMSE ranking was gypsum = DLP = SLA < PJP group. The RMSE ranges in the gypsum, DLP, PJP, and SLA groups at different times were 6.79 to 8.86 μm, 5.44 to 10.17 μm, 10.16 to 11.28 μm, and 10.94 to 32.74 μm, respectively. Although gypsum and printed preparation dies showed statistically significant differences in surface characteristics, accuracy, and dimensional stability, all tooth preparation dies were clinically tolerated and used to produce fixed restorations.

Fit and Strength of a Three-Unit Temporary Prosthesis Made by Different Manufacturing Techniques: An In Vitro Study.

To compare the fit and fracture load of temporary fixed partial prostheses fabricated by means of a conventional direct technique, milling, or 3D printing. A maxillary right first premolar and molar were prepared on a Frasaco cast, which was then duplicated 40 times. In total, 10 provisional three-unit fixed prostheses (Protemp 4, 3M) were made using the conventional technique with a putty mold. The 30 remaining casts were scanned to design a provisional restoration using CAD software. A total of 10 designs were milled (CEREC MC X5/shaded PMMA Disk, Dentsply Sirona), while the other 20 were 3D printed with one of the two 3D printers (Asiga UV MAX or Nextdent 5100, C&B, Nextdent). Internal and marginal fit were examined using the replica technique. Next, the restorations were cemented on their respective casts and loaded until fracture using a universal testing machine. The location and propagation of the fracture were also evaluated. 3D printing demonstrated the best internal fit. Nextdent (median internal fit: 132 μm) was significantly better compared to the milled (median internal fit: 185 μm; P = .006) and conventional restorations (median internal fit: 215 μm; P < .001), while the fit of Asiga (median internal fit: 152 μm) was only significantly better than the conventional restorations (P < .012). The lowest marginal discrepancy was found for the milled restorations (median marginal fit: 96 μm), but this was only significant when compared to the conventional group (median internal fit: 163 μm; P < .001). The conventional restorations demonstrated the lowest fracture load (median fracture load: 536 N), which was only significant when compared to Asiga (median fracture load: 892 N; P = .003). Within the present in vitro study's limitations, CAD/CAM demonstrated superior fit and strength compared to the conventional technique.

Artifact suppression and improved signal-to-noise ratio by phase-locked multiplexed coherent imaging.

Laser additive manufacturing (AM) promises direct metal 3D printing, but is held back by defects and process instabilities, giving rise to a need for in situ process monitoring. Inline coherent imaging (ICI) has proven effective for in situ, direct measurements of vapor depression depth and shape in AM and laser welding but struggles to track turbulent interfaces due to poor coupling back into a single-mode fiber and the presence of artifacts. By z-domain multiplexing, we achieve phase-sensitive image consolidation, automatically attenuating autocorrelation artifacts and improving interface tracking rates by 58% in signal-starved applications.

3D printed microfluidic valve on PCB for flow control applications using liquid metal

Direct 3D printing of active microfluidic elements on PCB substrates enables high-speed fabrication of stand-alone microdevices for a variety of health and energy applications. Microvalves are key components of microfluidic devices and liquid metal (LM) microvalves exhibit promising flow control in microsystems integrated with PCBs. In this paper, we demonstrate LM microvalves directly 3D printed on PCB using advanced digital light processing (DLP). Electrodes on PCB are coated by carbon ink to prevent alloying between gallium-based LM plug and copper electrodes. We used DLP 3D printers with in-house developed acrylic-based resins, Isobornyl Acrylate, and Diurethane Dimethacrylate (DUDMA) and functionalized PCB surface with acrylic-based resin for strong bonding. Valving seats are printed in a 3D caterpillar geometry with chamber diameter of 700 µm. We successfully printed channels and nozzles down to 90 µm. Aiming for microvalves for low-power applications, we applied square-wave voltage of 2 Vpp at a range of frequencies between 5 to 35 Hz. The results show precise control of the bistable valving mechanism based on electrochemical actuation of LMs.

Direct 4D printing of ceramics driven by hydrogel dehydration

4D printing technology combines 3D printing and stimulus-responsive materials, enabling construction of complex 3D objects efficiently. However, unlike smart soft materials, 4D printing of ceramics is a great challenge due to the extremely weak deformability of ceramics. Here, we report a feasible and efficient manufacturing and design approach to realize direct 4D printing of ceramics. Photocurable ceramic elastomer slurry and hydrogel precursor are developed for the fabrication of hydrogel-ceramic laminates via multimaterial digital light processing 3D printing. Flat patterned laminates evolve into complex 3D structures driven by hydrogel dehydration, and then turn into pure ceramics after sintering. Considering the dehydration-induced deformation and sintering-induced shape retraction, we develop a theoretical model to calculate the curvatures of bent laminate and sintered ceramic part. Then, we build a design flow for direct 4D printing of various complex ceramic objects. This approach opens a new avenue for the development of ceramic 4D printing technology.