Direct-write Printing Research Articles

Fabrication of flexible pressure sensor for human detection by direct-write printing concave surface

Flexible pressure sensor plays an important role in the field of human-computer interaction area due to its high flexibility and sensitivity. Convex surface of flexible electrodes provide an efficient way to enhance the sensitivity of flexible pressure sensors. However, facilely preparing controllable convex surface of flexible electrodes is still a challenge for obtaining high sensitive flexible pressure sensors. In this paper, direct-write print technique was utilized to prepare a concave structure surface with viscoelastic substrate, which could be used to prepare convex structure flexible electrode for fabricating highly sensitive flexible pressure sensors. Interaction between ink droplet and substrate was explored to generate a concave template, which could be controlled in spacing and diameter with printing spacing and nozzle diameter. Convex structure flexible surface could be prepared with the concave template, and then the convex structure flexible electrode could be realized with the evaporation of metallic silver on the surface. Furthermore, flexible pressure sensor was assembled with an interlocking structure by stacking two convex structure flexible electrodes in a face-to-face way, which could efficiently enhance flexibility and electrical property. The flexible pressure sensor presents a high sensitivity, a fast response/recovery time (<100 ms) and excellent flexibility (more than 10,000 cycles of bending), which could be applied in monitor physiological signals such as pulse detection, sound vibration, finger bending and so on. Therefore, this work provides an efficient method for preparing controllable structured surface, which has a great potential in the fabrication of flexible sensors, wearable electronics and energy devices.

Microfluidic Lab-on-CMOS Packaging Using Wafer-Level Molding and 3D-Printed Interconnects.

Lab-on-a-chip (LoC) technologies continue to promise lower cost and more accessible platforms for performing biomedical testing in low-cost and disposable form factors. Lab-on-CMOS or lab-on-microchip methods extend this paradigm by merging passive LoC systems with active complementary metal-oxide semiconductor (CMOS) integrated circuits (IC) to enable front-end signal conditioning and digitization immediately next to sensors in fluid channels. However, integrating ICs with microfluidics remains a challenge due to size mismatch and geometric constraints, such as non-planar wirebonds or flip-chip approaches in conflict with planar microfluidics. In this work, we present a hybrid packaging solution for IC-enabled microfluidic sensor systems. Our approach uses a combination of wafer-level molding and direct-write 3D printed interconnects, which are compatible with post-fabrication of planar dielectric and microfluidic layers. In addition, high-resolution direct-write printing can be used to rapidly fabricate electrical interconnects at a scale compatible with IC packaging without the need for fixed tooling. Two demonstration sensor-in-package systems with integrated microfluidics are shown, including measurement of electrical impedance and optical scattering to detect and size particles flowing through microfluidic channels over or adjacent to CMOS sensor and read-out ICs. The approach enables fabrication of impedance measurement electrodes less than 1 mm from the readout IC, directly on package surface. As shown, direct fluid contact with the IC surface is prevented by passivation, but long-term this approach can also enable fluid access to IC-integrated electrodes or other top-level IC features, making it broadly enabling for lab-on-CMOS applications.

Direct-Written Silver Electrodes for All-Solution-Processed Low-Voltage Organic Thin Film Transistors Towards Flexible Electronics Applications

Recent progress inprinted electronics has offered the possibility of fabricatingvarious organic-based electronic devices,such as organic light-emitting diodes (OLEDs) and organic thin film transistors (OTFTs).As one of the important deposition methods inprinted electronics, an inkjet printing technique offers the deposition of solution-processable materials onto a variety of substrates using simpler fabrication steps at lower processing temperatures, which is suitable for flexible electronic applications. Despite being the leading choice in OTFT fabrication,the clogging issues that frequently occurred at the printhead nozzle havenot only limitedthe material selection but also restrained the efforts to bring organic electronic devices to the market. Apart from that, although remarkable progress has been made to enhance the performance of the OTFT, the high operating voltage resulting from the low gate capacitance density of the inorganic oxide-based dielectric layer remains a critical limitation that hinders the practical application of the OTFT. Hence, in this paper, we propose a simple solution-based method to develop a low-voltageOTFT. This work utilized a direct-write printing technique to print silver source/drain and gate electrodes incorporated into a bottomgate bottom contact OTFT structure, a spin-coating deposition method to deposit both small molecule TIPS-pentacene organic semiconducting layer and high-kPVA dielectric layer. Notably, the proposed OTFT achieved a micrometre channel length with a saturation mobility of 4.49 × 10-1cm2/Vs, a threshold voltage of -1.5V, an on/off current ratio of 108, and a subthreshold swing of 66.8mV/dec whilethe overall fabrication temperature and operating voltage arekept below 150 °Cand -15 V, respectively.The direct ink writing technology incorporated into the high-kdielectric layer provides a new strategy to fabricate organic-related components,particularly the OFTFs at lower manufacturing cost and temperature towardsflexible and low-operating voltage electronic devices.

Reliability Assessment and Multi-Physics Simulation of Additively Printed Wearable Humidity Sensor with Super Capacitive Material for Astronaut in Extreme Condition

Abstract Additive technologies, such as aerosol jet printing, direct write printing are increasingly being used in the production of printed circuit boards because they eliminate the need for costly tooling, such as photomasks or etching containers. This is because additive methods allow for the direct deposition of printing materials onto a substrate. This versatility in a broad variety of applications allows engineers to create diverse applications, such as sensing devices with ECG sensors, pulse-oxygen sensors, galvanic skin response sensors, body temperature sensors, humidity sensors, and so on. Due to its potential for adaptability and integration, the development of additively printed humidity sensors has been the subject of several prior investigations. There are still issues with the reliability of current humidity sensor technology when flexing force is coupled with the humidity sensor. For the avoidance of stability issues, it is required to develop a better printing technique, process recipe, and sensing material encapsulation. In this research, the direct-write (D-write) printing approach with a nScrypt printer was employed to print the humidity sensor as a test vehicle in a laboratory setting. The sensor was characterized by analyzing the print recipe and its interaction with humidity in regards to resistance and humidity sensitivity. Additionally, the characterization of sensor accuracy, hysteresis, linearity, and stability in relation to temperature and humidity variation has been measured. Furthermore, a multi-physics simulation model was created in order to comprehend the electrochemical processes that occur when the humidity sensor is exposed to a very humid environment.

Fabrication of ultra-precise flexible electrothermal film by direct-write printing porous graphene-Ag structure

In this study, graphene oxide (GO)‑silver nitrate (AgNO3) composite ink was prepared with stable printability, which could match the direct-write print technique for patterning GO-AgNO3 composite structure. Reduced graphene oxide (rGO)‑silver (Ag) porous structure could be obtained with a freeze-drying and gas phase reduction process. The rGO-Ag porous structure could reach a conductivity of 3.2 × 105 S/m through quantum penetration effect with the bridging action. Subsequently, polydimethylsiloxane (PDMS) encapsulated the rGO-Ag porous structure, and a special composite structure of PDMS/ rGO-Ag/PDMS films could be obtained by adjusting the wetting effect. PDMS provided a good tensile property and excellent bending resistance, and then a relative resistance changes within 5 % could be achieved after the number of 10,000 bending times. With the rGO-Ag porous structure compressed into a thinner film, an ultra-precise flexible electrothermal performance could be realized with the conductive network and flexible package structure. The surface temperature of fabricated composite film could reach 201.3 °C at the voltage of 7 V, within a heating time of 25 s, and maintaining the temperature for 1800 s. Meanwhile, the flexible electrothermal film could keep a stable temperature after 120 power on/power off cycles. Furthermore, the flexible electrothermal film also has a linear temperature control ability, which could carry out the linear temperature control with different temperature regions. At last, the ultra-precise flexible electrothermal film exhibits an excellent applying effect for the wrist hot compress, pipeline heating and window cleaning with uneven ice thickness. Therefore, the direct-write printed porous graphene-Ag structure presents a special property for fabricating ultra-precise flexible electrothermal film, which could provide a great research significance and application value in printing electronic structure and manufacturing electronic device.

Enhanced mass transfer by 3D printing to promote the degradation of organic pollutants in electro-Fenton system

In this study, researchers constructed a monolithic 3D-FeO/C electrode with a macro-ordered pore structure using direct-write 3D printing technology. Experimental results showed that the 3D-FeO/C electrode possessed excellent degradation performance for ornidazole (ONZ) (complete degradation within 120 min) and pharmaceutical wastewater (51.13 % in TOC and 63.72 % in COD removal within 420 min). The detailed reaction mechanism of the EF system was revealed through characterization analysis, mass transfer simulation, and experimental results, in which the excellent EF performance is mainly due to the confinement effect of FeO active sites encapsulated in the carbon layer, as well as the enhancement of mass transfer induced by 3D printing macro-ordered structure network. In addition, the degradation pathway of ONZ, the toxicity of its degradation intermediates, and the degradation pathway of actual pharmaceutical wastewater were revealed in detail. This study proposes a new 3D printing method to enhance the mass transfer of electrode materials in EF systems, which has good potential for application to real wastewater.

Feasibility assessment of polyvinyl alcohol-based bioresorbable cardiovascular stents manufactured via solvent-cast direct writing extrusion

BackgroundBioresorbable stents represent a promising approach in cardiovascular interventions compared to drug-eluting stents. Additive manufacturing, particularly ink deposition, offers customization and versatility. This study delves into the potential of solvent cast direct-write 3D printing to fabricate cardiovascular stents using environmentally friendly solvents. MethodologyPolyvinyl alcohol, a biocompatible synthetic polymer that dissolves in water, was investigated as a suitable material for stent fabrication. The polymer was deposited on a rotating mandrel and subsequently crosslinked to establish a pseudostable state. Test specimens and stents were fabricated for characterization of both the material and stent dynamics. ResultsThis outcome is potentially suitable for deployment in the human body environment and adaptable to various biomedical applications, such as drug delivery patches or implants. The research optimized the fabrication of various stent geometries using polyvinyl alcohol and evaluated the kinetics of the working environment of these stents. Specifically, the 8-cell diamond stent showed remarkable characteristics, such as a high overexpansion of more than 0.5 mm, a compression force of 0.02 N and an elastic recovery of 88.85 %, with a strut thickness of 50.25 μm. Additionally, the study discusses the possibility of sterilizing polyvinyl alcohol with different methods, ethanol and autoclave were selected. ConclusionsThe results indicate that autoclaving leads to an increase in crystallinity. This yields a decrease in water absorption and an increase in mechanical properties. These results suggest that polyvinyl alcohol-based stents fabricated by solvent-cast direct writing are potential candidates for bioresorbable stent design.

All Solution Processable OTFT-Based on Direct-Written Printing Method Towards Flexible Electronics Applications

Development of organic electronics, particularly organic thin film transistors (OTFTs), have been centred of discussion among researchers due to their potential uses in flexible electronics applications. Conventionally, an inkjet printing method has been deployed to fabricate the OTFTs due to its simplicity in fabrication steps and applicability to diverse substrates and solution-processable materials. Nonetheless, this technique has a major drawback which requires low viscosity materials to prevent clogging issue at the printer’s nozzle. This in return limits the material selections and requires additional steps i.e. modification of the selected materials to fit the printer’s requirement or in other words, to avoid clogging at the nozzle. Therefore, this paper proposes a method to fabricate a bottom gate bottom contact (BGBC) OTFT by using a direct-write printing technique which is compatible with a commercial conductive ink that can be directly used without any further modification. This technique does not compromise the fabricated devices overall performance and can fabricate the devices up to micrometre scale. The proposed OTFT achieved a saturation mobility of 4.28x10-5 cm2/Vs, a threshold voltage of -0.4 V, an on/off current ratio of 102, and a subthreshold swing of 10 V/dec with overall fabrication temperature is less than 150 ℃, hence, makes it suitable for flexible electronics applications.

Direct-write 3D printing of plasmonic nanohelicoids by circularly polarized light

Chiral plasmonic surfaces with 3D "forests" from nanohelicoids should provide strong optical rotation due to alignment of helical axis with propagation vector of photons. However, such three-dimensional nanostructures also demand multi-step nanofabrication, which is incompatible with many substrates. Large-scale photonic patterns on polymeric and flexible substrates remain unattainable. Here, we demonstrate the substrate-tolerant direct-write printing and patterning of silver nanohelicoids with out-of-plane 3D orientation using circularly polarized light. Centimeter-scale chiral plasmonic surfaces can be produced within minutes using inexpensive medium-power lasers. The growth of nanohelicoids is driven by the symmetry-broken site-selective deposition and self-assembly of the silver nanoparticles (NPs). The ellipticity and wavelength of the incident photons control the local handedness and size of the printed nanohelicoids, which enables on-the-fly modulation of nanohelicoid chirality during direct writing and simple pathways to complex multifunctional metasurfaces. Processing simplicity, high polarization rotation, and fine spatial resolution of the light-driven printing of stand-up helicoids provide a rapid pathway to chiral plasmonic surfaces, accelerating the development of chiral photonics for health and information technologies.

Research on rice starch gel preparation and crosslink network structure-rheological property based on direct-writing 3D printing

Amylopectin and amylose components are natural polymers within rice starch granules, intertwined in specific conditions to form gel polymerized with pore crosslink network, has potential printing properties. In this study, a rice starch gel preparation scheme is proposed for stable properties, and starch granule phase transition mechanism is analyzed based on RVA test during preparation, it can be divided into four-stage, swelling, reacting, homogenizing and self-assembling stages. Gel surface tension and contact angle tested with starch concentration effect, a correlation is developed, reflecting a competition result to gel droplet macro-morphology between the intermolecular cohesion and crosslink network. SEM is used to reveal typical crosslink structures of different starch molecular component proportions, providing objective support for starch gel rheologic property change. Results indicate gel interior crosslink network formed under concentration 12 %, the gel with amylose 4.475 % presents better printing accuracy. Gel shear modulus positively correlated with amylose proportion. Japonica gel under 20 % is of higher viscosity and rapid reassembly ability after interior crosslink network is broken. Max dynamic viscosity is positively correlated with starch concentration. The study aims to provide theoretical and practical support for in-depth analysis of rice starch material application in direct-write 3D printing.

Synergistic Effect of Physical and Chemical Cross-Linkers Enhances Shape Fidelity and Mechanical Properties of 3D Printable Low-Modulus Polyesters.

Three-dimensional (3D) printing is becoming increasingly prevalent in tissue engineering, driving the demand for low-modulus, high-performance, biodegradable, and biocompatible polymers. Extrusion-based direct-write (EDW) 3D printing enables printing and customization of low-modulus materials, ranging from cell-free printing to cell-laden bioinks that closely resemble natural tissue. While EDW holds promise, the requirement for soft materials with excellent printability and shape fidelity postprinting remains unmet. The development of new synthetic materials for 3D printing applications has been relatively slow, and only a small polymer library is available for tissue engineering applications. Furthermore, most of these polymers require high temperature (FDM) or additives and solvents (DLP/SLA) to enable printability. In this study, we present low-modulus 3D printable polyester inks that enable low-temperature printing without the need for solvents or additives. To maintain shape fidelity, we incorporate physical and chemical cross-linkers. These 3D printable polyester inks contain pendant amide groups as the physical cross-linker and coumarin pendant groups as the photochemical cross-linker. Molecular dynamics simulations further confirm the presence of physical interactions between different pendants, including hydrogen bonding and hydrophobic interactions. The combination of the two types of cross-linkers enhances the zero-shear viscosity and hence provides good printability and shape fidelity.

Numerical Simulation and Optimization of Stable Coaxial Jet Formation and Direct-Write Printing Array Nanoarchitectonics

Numerical Simulation and Optimization of Stable Coaxial Jet Formation and Direct-Write Printing Array Nanoarchitectonics

Flexible low profile UWB antenna on polyimide film based on silver nanoparticle direct-write dispenser printing for wireless applications

Flexible low profile UWB antenna on polyimide film based on silver nanoparticle direct-write dispenser printing for wireless applications

Direct-Write Printed Wearable Metasurfaces

Direct-write printing was utilized in fabricating a wearable metasurface for frequency filtering at 6 GHz. Using radio frequency (RF) performance and sheet resistance, Rs as performance metrics, the printed metasurfaces were subjected to wash cycle and longevity testing. The metasurface was printed on two woven nylon industrial fabrics (70D (EX) and 200D (BW) thread masses) featuring a polyurethane (PU) coating on one side. Two conductive inks, CM127-48 (Creative Materials) and PE876 (Dupont) were printed on the fabrics and tested for Rs , RF performance, wash cycle stability, and longevity. Rs values for CM127-48 on EX and BW were similar (0.083±0.013 and 0.088±0.031 ohm/sq, respectively), while PE876 had higher Rs , on BW than EX (0.080±0.015 and 0.35±0.06 ohm/s). RF performance revealed that S21 magnitudes were at least −30 dB for all four ink–fabric combinations, in agreement with simulations. Wash cycle testing of PE876 on EX and BW revealed a comparable decrease in S21 magnitude for both fabrics. However, BW samples exhibited minimal shifts in peak frequency. Longevity tests on the four ink–fabric combinations demonstrated that S21 magnitudes were at least −29.5 dB, with the smallest change in magnitude for the CM127-48–EX sample. Materials selection may be tailored for various design goals in wearable electronics.

Depletion attraction driven formation of Spirulina emulsion gels for 3D printing

3D printing has been applied to create nutritious foods with tailored textures for the elderly. However, the edible materials that possess the elastoplastic properties and shear-thinning behavior required for direct-write 3D printing are limited. In this study, we developed a simple approach to fabricate Spirulina emulsion gels as edible 3D printable material by exploiting depletion attraction between emulsion droplets. By controlling the volume ratio of continuous and oil phases, mixing highly viscous Spirulina slurry and vegetable oil could form self-standing oil-in-water emulsion gels with elastoplastic rheological properties. Also, adding food polysaccharides into the continuous phase could act as depletants to drive the formation of emulsion gels. Auto-fluorescence spectroscopy and microscopy were employed to characterize the interfacial protein compositions of the emulsion, showing that phycobilisome (PBS) particles might play a dominant role in the formation of Spirulina emulsions. The depletion attraction could drive the adsorption of PBS particles onto the droplet interface, and the particle-armored droplets in the dispersed phase connected into a percolating droplet cluster, resulting in arrested dynamics and gelation. Overall, this novel approach can be applied by exploiting depletion attraction and opens up possibilities for using high-solids viscous food slurries to produce personalized 3D-printed foods.

Experimental Investigation of High-Viscosity Conductive Pastes and the Optimization of 3D Printing Parameters

Traditional contact printing technology is primarily controlled by the shape of the mask to form the size, while for the more popular non-contact printing technologies, in recent years, adjusting the print parameters has become a direct way to control the result of the printing. High-viscosity conductive pastes are generally processed by screen printing, but this method has limited accuracy and wastes material. Direct-write printing is a more material-efficient method, but the printing of high-viscosity pastes has extrusion difficulties, which affects the printed line width. In this paper, we addressed these problems by studying the method of printing high-viscosity conductive paste with a self-made glass nozzle. Then, by parameter optimization, we achieved the minimum line width printing. The results showed that the substrate moving speed, the print height, and the feed pressure were the key factors affecting the line width and stability. The combination of the printing parameters of 0.6 MPa feed pressure, 200 mm/s substrate moving speed, and 150 μm print height can achieve a line width of approximately 30 μm. In addition, a mathematical model of the line width and parameters was established, and the prediction accuracy was within 5%. The results and the prediction model of the parameters provide an important reference for the printing of high-viscosity pastes, which have immense potential applications in electronics manufacturing and bioprinting.

Ultraviolet-assisted direct-write printing strategy towards polyorganosiloxane-based aerogels with freeform geometry and outstanding thermal insulation performance

Developing aerogels with a tailored geometric feature is of prime importance for enlarging their functional effects in application scenarios. However, conventional manufacturing techniques have remained challenging in the on-demand shaping of aerogels due to their costly and time-consuming fabrication process and poor designability of casting molds. Herein, an ultraviolet-assisted direct-write printing strategy has been proposed for fabricating polyorganosiloxane-based aerogels with tunable molecular triple-crosslinks consisting of hydrogen bonds, hydrocarbon chains, and polysiloxanes. The implementation of direct-write printing depends on the close synergy of consecutive ink deposition and instantaneous photopolymerization, appearing as a considerable characteristic of solidification-while-printing, which is conducive to constructing spatially freeform geometries with high structural complexity and shape fidelity. The resultant 3D-printed polyorganosiloxane-based aerogels exhibit outstanding nanoporous performances, such as low density (0.14 g·cm−3), high surface area (484 m2·g−1), superhydrophobicity (water contact angle, 150°), high specific modulus (27.9 kN·m·kg−1), and low thermal conductivity (37.48 mW·m−1·K−1), which are ideal materials for shape-dominated thermal insulation applications. This work would provide an alternative printing strategy to fabricate nanoporous materials with arbitrary architectures for wider applications.

3D direct-write printing of water soluble micromoulds for high-resolution rapid prototyping.

Direct-write printing has contributed tremendously to additive manufacturing; in particular extrusion based printing where it has extended the range of materials for 3D printing and thus enabled use across many more sectors. The printing inks for direct-write printing however, need careful synthesis and invariably undergo extensive preparation before being able to print. Hence, new ink synthesis efforts are required every time a new material is to be printed; this is particularly challenging for low storage modulus (G') materials like silicones, especially at higher resolutions (under 10µm). Here we report the development of a precise (< 10µm) 3D printable polymer, with which we 3D print micromoulds which are filled with standard silicones like polydimethylsiloxane (PDMS) and left to cure at room temperature. The proof of concept is demonstrated using a simple water soluble polymer as the mould material. The approach enables micrometre scale silicone structures to be prototyped with ease, away from the cleanroom.

Direct-write 3D printing of UV-curable composites with continuous carbon fiber

Continuous fiber-reinforced polymer composites, with their superior combinations of high stiffness, high strength, lightweight, and corrosion resistance, have been leading contenders in various applications ranging from aerospace to ground transportation. The integration with 3D printing allows the composite products to be customized quickly and fabricated inexpensively to meet unique specifications. However, the material-process-property relationships of 3D printed thermoset composites with continuous fiber are insufficiently explored in the field. In this work, a cost-effective 3D printing method is developed based on the direct ink writing method to print UV-curable composites reinforced with continuous carbon fiber. During the printing, the fiber tow is impregnated with an acrylate ink inside the printer head and then extruded onto the printer bed, where it is cured upon UV irradiation. The influences of different material and processing variables, such as the resin viscosity, nozzle size, printing speed, and substrate temperature, on the quality and mechanical properties of composites, are investigated. The porosity, stiffness, and strength of printed symmetric laminate are also examined. Finally, the 3D printing of composite structures and the conformal coating of curved surfaces along a defined printing path are demonstrated. The findings reported in this work could contribute to the rapid design and manufacturing of composite components with unprecedented mechanical properties and emerging functionalities for the automotive, defense, and aerospace industries.

Solvent-assisted precipitation direct-write printing toward in-suit oriented β-phase polyvinylidene fluoride with tunable microarchitectures for energy harvesting and self-powered sensing

Additive manufacturing technology has attracted significant attention because it facilitates the one-step fabrication of complex structures for piezoelectric devices. In this study, a facile approach is proposed for manufacturing complex piezoelectric nanogenerators (PENGs) with an in-suit oriented β-phase of polyvinylidene fluoride (PVDF) based on solvent-assisted precipitation direct-write three-dimensional (3D) printing (SPDWP). This SPDWP has the ability to fabricate porous structures owing to the rapid nonsolvent-induced phase separation and controllable porosity of the fiber. In particular, the SPDWP based on ethanol precipitation increases the β-phase content of PVDF to 76.21%, representing a 1.5-fold improvement compared to that by the solvent casting technique. Moreover, the shape of the printed fiber—impacted by the printing parameters—significantly influences the piezoelectric performance. In particular, cylindrical fiber-based PENGs exhibit better piezoelectric performance than elliptical fiber-based PENGs, producing a higher voltage output of 11.3 V owing to the structural deformation, as confirmed by the simulation results. As expected, these printed PENGs can detect a variety of human movements, demonstrating that SPDWP is a novel method for fabricating 3D structural PENGs for self-powering microelectronic applications with the advantages of achieving geometric complexity, manufacturing simplicity, and low cost.