Flexible Fabrication Research Articles

Design and optimization of a novel solenoid with high magnetic uniformity

Currently, solenoids are extensively utilized in various research fields due to their flexibility of fabrication and high magnetic field strength. However, the internal magnetic field of the solenoid itself exhibits some non-uniformity defects, which limits its application in some domains. This article proposes a novel single winding tightly wound solenoid structure with an improved magnetic field uniformity. To optimize the magnetic field near the aperture of the conventional solenoid, an auxiliary solenoid with a gradually changing diameter is included at each end of the solenoid. By adjusting different parameters of the auxiliary solenoid, the edge effect of the solenoid was reduced, and its overall magnetic field uniformity was improved. The optimization of the auxiliary solenoids is achieved through GA-KAN network techniques. Finite element simulation results with the optimized parameters show that the proportion of uniform areas can be improved by more than five times. The research results are a reference for high-precision electromagnetic sensing applications based on solenoids.

Carbon Nanotubes and Their Composites for Flexible Electrochemical Biosensors

AbstractFlexible biosensors play a crucial role for healthcare management and disease diagnosis. Electrochemical biosensors have attracted significant attention for wearable sensing applications owing to their numerous advantages, including high sensitivity and selectivity, inherent miniaturization and rapid response times. Challenges lie in the development of highly conductive and flexible electrodes that can be integrated with biorecognition components to engineer selective biosensor interfaces. Carbon nanotubes (CNTs) hold significant promise as materials for wearable flexible sensor fabrication. This review highlights recent strategies for fabricating conductive and flexible electrodes, whether in the form of films or fibers, based on CNTs and their composites. Additionally, the review explores emerging biosensing applications, including flexible sensors for the direct electrochemical detection of biomarkers, sensors functionalized with enzymes, antibodies, or DNA, and sensors interfaced with cells to monitor transient biochemical signals.

Controlled Fabrication of Wafer-Scale, Flexible Ag-TiO2 Nanoparticle-Film Hybrid Surface-Enhanced Raman Scattering Substrates for Sub-Micrometer Plastics Detection.

As an important trace molecular detection technique, surface-enhanced Raman scattering (SERS) has been extensively investigated, while the realization of simple, low-cost, and controllable fabrication of wafer-scale, flexible SERS-active substrates remains challenging. Here, we report a facile, low-cost strategy for fabricating wafer-scale SERS substrates based on Ag-TiO2 nanoparticle-film hybrids by combining dip-coating and UV light array photo-deposition. The results show that a centimeter-scale Ag nanoparticle (AgNP) film (~20 cm × 20 cm) could be uniformly photo-deposited on both non-flexible and flexible TiO2 substrates, with a relative standard deviation in particle size of only 5.63%. The large-scale AgNP/TiO2 hybrids working as SERS substrates show high sensitivity and good uniformity at both the micron and wafer levels, as evidenced by scanning electron microscopy and Raman measurements. In situ bending and tensile experiments demonstrate that the as-prepared flexible AgNP/TiO2 SERS substrate is mechanically robust, exhibiting stable SERS activity even in a large bending state as well as after more than 200 tensile cycles. Moreover, the flexible AgNP/TiO2 SERS substrates show excellent performance in detecting sub-micrometer-sized plastics (≤1 μm) and low-concentration organic pollutants on complex surfaces. Overall, this study provides a simple path toward wafer-scale, flexible SERS substrate fabrication, which is a big step for practical applications of the SERS technique.

Rate-dependent mechanical and self-monitoring behaviors of 3D printed continuous carbon fiber composites

3D printed continuous carbon fiber reinforced polymer (CFRP) composites offer great advantages in structural health monitoring (SHM) owing to their flexibility in complex structure fabrication. Considering the many prospective aerospace applications, tensile experiments were designed to study their mechanical and self-sensing behaviors under a wide range of strain rates. The turning points in the resistance vs strain curves reveal the damage evolution of the specimens and divide the deformations into linear straining and damage evolution regions. Fiber elongation and fiber contact reduction dominate the resistance increase in the linear straining region and the resistance curve behaves linearly. But fiber breakage is the predominant factor in the damage evolution region, yielding a concave resistance curve. Strength, fracture strain, and resistance variation are found to display significant strain rate dependencies that increase with increasing strain rate. Numerous microcracks are formed and evolved into secondary cracks under dynamic loading. This process absorbs more strain energy and produces more carbon fiber breaks, sustaining a higher fracture strain and resistance variations. A model is developed to describe the strain- and strain rate- dependent resistance behaviors, and the predicted results agree well with experimental data. The outcomes of this work contribute to the application of 3D printed continuous CFRP composites in SHM.

Femtosecond laser-induced plasma-assisted backward deposition of robustly adherent porous carbon films on glass substrates

The simple and rapid production and transfer of high-quality carbon materials are crucial for the flexible and efficient fabrication of carbon-based electronic devices. Recently, a laser-assisted transfer method combining laser-induced carbonization and transfer printing was demonstrated for the one-step preparation and transfer of patterned laser-induced carbon films to transparent substrates. However, this method is limited by insufficient robustness and weak adhesion of the carbon film post-transfer. Herein, we developed a non-contact laser-induced plasma-assisted deposition method to deposit robustly adherent porous carbon films on glass substrates. By well-adjusting the laser parameters and inserting spacers with adjustable thickness, laser-induced plasma ablation replaced direct laser ablation during femtosecond laser scanning of the substrate-polyimide-carrier sandwich structure, resulting in micro-channels with a carbon-glass recast layer instead of easily peelable flakes on the glass substrate. This hierarchical structure significantly enhances the adhesion between the laser-induced carbon film and the glass substrate, ensuring outstanding stability of the deposited carbon film under various adhesion tests. Furthermore, compared to carbon films prepared by the laser-assisted transfer method, the obtained carbon films are hydrophilic, low-resistance, and porous, facilitating the fabrication of energy storage devices. To demonstrate its practical application, a planar carbon-based micro-supercapacitor was fabricated on glass, exhibiting excellent electrochemical and cycling performance.

Picosecond photoacoustic generation of ultrasounds with composites of graphene-decorated gold nanoparticles

Photoacoustic or light-to-pressure transducer materials exhibit tremendous potential across various disciplines and applications, embracing theragnostic ultrasounds and permeabilization of biological barriers for drug delivery or for gene transfection. Here, we report the photoacoustic response in the picosecond excitation regime of graphene and gold nanoparticles decorated graphene dispersed in a polydimethylsiloxane polymer matrix. A novel decoration method was developed to nucleate Au nanoparticles of 25 nm on the graphene surface without reducing agent. We observed that the picosecond excitation enforced by the stress confinement generates high-frequency waves, with bandwidths of −6 dB and −20 dB of around 70 MHz and 130 MHz respectively, and peak pressure > 5 MPa. Further, the presence of gold surface decoration leads to a better dispersibility of the flake into the polymer matrix and to an increasing bandwidth at −6 dB up to 85 MHz. The decrease in source thickness leads to an increase in ultrasound frequency, which retains its value even when the laser fluence is increased up to 150 mJ cm –2. This enables the generation of high pressures while keeping the same bandwidth. We experimentally show that the photoacoustic waveform can be tailored by changing the temporal duration of the laser light, the geometry of the acoustic source, and the nature of the graphene absorber. Flexible decoration and fabrication methods of thin films, along with the generation of high-frequency and high-pressure ultrasound waves, offer new perspectives for the use of physical methods to permeabilize biological barriers and develop high-resolution photoacoustic imaging systems.

Flexible fabrication of core/shell nanoparticles for tailored infrared emissivity on aluminum via femtosecond laser self-deposition.

A metal surface with controllable infrared emissivity has a wide range of applications. However, a flexible and simple fabrication method is needed. Here, a controllable femtosecond laser self-deposition technology was developed to fabricate Al@AlOx core/shell micropillars (MPs) with diverse size distribution on the aluminum surface in a single-step operation under ambient conditions. By establishing a deterministic relationship between pulse-repetition frequency (PRF) and particle size distribution (PSD), we achieved continuous control of the infrared emissivity of the surface by lower PRF, ranging from low (0.31) to high (0.93). Additionally, by using higher PRF, we attained dual-band emissivity control, featuring high emissivity in the range of 10-14 µm and near-continuous change in the range of 2.5-10 µm.

Overcoming Microstructural Defects at the Buried Interface of Formamidinium-Based Perovskite Solar Cells.

Since the advent of formamidinium (FA)-based perovskite photovoltaics (PVs), significant performance enhancements have been achieved. However, a critical challenge persists: the propensity for void formation in the perovskite film at the buried perovskite-interlayer interface has a deleterious effect on device performance. With most emerging perovskite PVs adopting the p-i-n architecture, the specific challenge lies at the perovskite-hole transport layer (HTL) interface, with previous strategies to overcome this limitation being limited to specific perovskite-HTL combinations; thus, the lack of universal approaches represents a bottleneck. Here, we present a novel strategy that overcomes the formation of such voids (microstructural defects) through a film treatment with methylammonium chloride (MACl). Specifically, our work introduces MACl via a sequential deposition method, having a profound impact on the microstructural defect density at the critical buried interface. Our technique is independent of both the HTL and the perovskite film thickness, highlighting the universal nature of this approach. By employing device photoluminescence measurements and conductive atomic force microscopy, we reveal that when present, such voids impede charge extraction, thereby diminishing device short-circuit current. Through comprehensive steady-state and transient photoluminescence spectroscopy analysis, we demonstrate that by implementing our MACl treatment to remedy these voids, devices with reduced defect states, suppressed nonradiative recombination, and extended carrier lifetimes of up to 2.3 μs can be prepared. Furthermore, our novel treatment reduces the stringent constraints around antisolvent choice and dripping time, significantly extending the processing window for the perovskite absorber layer and offering significantly greater flexibility for device fabrication.

Dynamic fluorescent patterns inspired by cuttlefish for anti-counterfeiting applications

Dynamic fluorescent patterns that convert external stimulation into intuitive color changes have drawn significant interest in various fields. However, the complex synthesis of materials with multiple emissions and technical barriers in the flexible fabrication of full-color fluorescent patterns hinder their applicability in diverse scenarios. Here, we present a bioinspired dynamic fluorescent pattern fabricated by femtosecond laser-induced forward transfer (FsLIFT), inspired by cuttlefish. The elastomeric substrate can contract and expand as muscle fibers of cuttlefish, and the patterned red, green, and blue quantum dot (QD) films can be regarded as pigment cells, achieving bionic preparation of function and morphology similar to cuttlefish. Notably, the fluorescent patterns can be modulated by manipulating strains and excitations. Using this bioinspired strategy, we successfully produced an advanced fluorescent anti-counterfeiting label via FsLIFT, which can only be recognized under specific strain and excitation light conditions. These dynamic fluorescent patterns show broad application potential in anti-counterfeiting, wearable devices, and information encryption.

Strain‐Modulated Hydrogen Production Performance in Monolayer MoS2 Electrocatalysis Nanodevices

AbstractThe integration of flexible micro‐ and nanodevices plays a pivotal role in investigating stress‐enhanced performances and underlying intrinsic mechanisms for two‐dimensional materials. This study presents the fabrication of single‐crystal flexible devices using monolayer MoS2 and its catalytic activities for the hydrogen evolution reaction under stress conditions. A metallic conductive layer was deposited on the photoresist surface via magnetron sputtering, overcoming the challenges associated with lithography on insulating substrates using electron beam lithography (EBL). The results demonstrate optimal etch patterns with a metal modification layer thickness of 10.97 nm. Leveraging this flexible device fabrication process, a single‐layer MoS2 single‐nanosheet flexible micro/nano device was developed and subsequently strain‐modulated (stretched along the zigzag lattice direction with the armchair lattice direction as the axis). A significant enhancement is observed in the electrocatalytic hydrogen evolution performance as the strain increases from 0 % to 0.40 %. Notably, the onset overpotential decreased from 155.6 to 95.7 mV, and the Tafel slope decreased from 175.3 to 98.6 mV dec−1. This study provides new insights into the design and performance of strain devices for two‐dimensional (2D) monocrystalline/polycrystalline materials.

Flexible ammonium ion-selective electrode based on inkjet-printed graphene solid contact

Miniaturization and mass-production of potentiometric sensor systems is paving the way towards distributed environmental sensing, on-body measurements and industrial process monitoring. Inkjet printing is gaining popularity as a highly adaptable and scalable production technique. Presented here is a scalable and low-cost route for flexible solid-contact ammonium ion-selective electrode fabrication by inkjet printing. Utilization of inkjet-printed melamine-intercalated graphene nanosheets as the solid-contact material significantly improved charge transport, while evading the detrimental water-layer formation. External polarization was investigated as a means of improving the inter-electrode reproducibility: the standard deviations of E0 values were reduced after electrode polarization, the linear region of the response was extended to the range 10−1–10−6 M of NH4Cl and LODs reduced to 0.88 ± 0.17 μM. Finally, we have shown that the electrodes are adequate for measurements in a complex real sample: ammonium concentration was determined in landfill leachate water, with less than 4 % deviation from the reference method.

Wafer-Scale Growth and Transfer of High-Quality MoS2 Array by Interface Design for High-Stability Flexible Photosensitive Device.

Transition metal disulfide compounds (TMDCs) emerges as the promising candidate for new-generation flexible (opto-)electronic device fabrication. However, the harsh growth condition of TMDCs results in the necessity of using hard dielectric substrates, and thus the additional transfer process is essential but still challenging. Here, an efficient strategy for preparation and easy separation-transfer of high-uniform and quality-enhanced MoS2 via the precursor pre-annealing on the designed graphene inserting layer is demonstrated. Based on the novel strategy, it achieves the intact separation and transfer of a 2-inch MoS2 array onto the flexible resin. It reveals that the graphene inserting layer not only enhances MoS2 quality but also decreases interfacial adhesion for easy separation-transfer, which achieves a high yield of ≈99.83%. The theoretical calculations show that the chemical bonding formation at the growth interface has been eliminated by graphene. The separable graphene serves as a photocarrier transportation channel, making a largely enhanced responsivity up to 6.86mAW-1, and the photodetector array also qualifies for imaging featured with high contrast. The flexible device exhibits high bending stability, which preserves almost 100% of initial performance after 5000 cycles. The proposed novel TMDCs growth and separation-transfer strategy lightens their significance for advances in curved and wearable (opto-)electronic applications.

Seed-guided high-repetition-rate femtosecond laser oxidation for functional three-dimensional silicon structure fabrication

Laser oxidation provides a flexible maskless functional three-dimensional silicon structure fabrication strategy. Here, oxide layers are fabricated on silicon substrates by high-repetition-rate femtosecond laser irradiation. Formation mechanisms of the femtosecond laser oxidation are analyzed to tune the oxide layer morphology. When the laser fluence is high, the oxidation process is accompanied by laser ablation, so the oxide layer is always on top of laser ablated groove. To obtain the flat oxide layer, defect is firstly generated on silicon substrate by the laser irradiation at a high laser fluence of 126 mJ/cm2, function as a high optical absorption. It is called seed as it can assist to achieve lower fluence laser oxidation at 38 mJ/cm2 and result in a flat oxide layer. Full width at half-maximum of the oxide layer is also reduced. The laser fabricated oxide layers are used as etching masks. Three-dimensional silicon gratings are fabricated by deep reactive ion etching, which demonstrate desirable beam diffraction properties.

Performance Projection of Vacuum Gate Dielectric Doping-Free Carbon Nanoribbon/Nanotube Field-Effect Transistors for Radiation-Immune Nanoelectronics.

This paper investigates the performance of vacuum gate dielectric doping-free carbon nanotube/nanoribbon field-effect transistors (VGD-DL CNT/GNRFETs) via computational analysis employing a quantum simulation approach. The methodology integrates the self-consistent solution of the Poisson solver with the mode space non-equilibrium Green's function (NEGF) in the ballistic limit. Adopting the vacuum gate dielectric (VGD) paradigm ensures radiation-hardened functionality while avoiding radiation-induced trapped charge mechanisms, while the doping-free paradigm facilitates fabrication flexibility by avoiding the realization of a sharp doping gradient in the nanoscale regime. Electrostatic doping of the nanodevices is achieved via source and drain doping gates. The simulations encompass MOSFET and tunnel FET (TFET) modes. The numerical investigation comprehensively examines potential distribution, transfer characteristics, subthreshold swing, leakage current, on-state current, current ratio, and scaling capability. Results demonstrate the robustness of vacuum nanodevices for high-performance, radiation-hardened switching applications. Furthermore, a proposal for extrinsic enhancement via doping gate voltage adjustment to optimize band diagrams and improve switching performance at ultra-scaled regimes is successfully presented. These findings underscore the potential of vacuum gate dielectric carbon-based nanotransistors for ultrascaled, high-performance, energy-efficient, and radiation-immune nanoelectronics.

Flexible and Multifunctional Composites with Highly Strain Sensing and Impact Resistance Properties.

The development of smart protective clothing will help detect injuries from contact sports, traffic collisions, and other accidents. The combination of ecoflex, spacer fabric, and graphene-based aerogel provides a multifunctional composite. It shows a strain sensitivity of 17.71 at the strain range of 40~55%, a pressure sensitivity of 0.125 kPa-1 at the pressure range of 0~15 kPa, and a temperature sensitivity of -0.648 °C-1. After 50 impact tests, its protection coefficient only dropped from 60% to 55%. Additionally, it shows thermal insulation properties. The compression and impact process results of finite element numerical simulation analysis are in good agreement with the experimental results. The ecoflex/aerogel/spacer fabric sensor exhibits a simple structure, large pressure strain, high sensitivity, flexibility, and ease of fabrication, making it a candidate for smart protective clothing resistant to impact loads.

Self-Powered cobalt nanocluster decorated flexible graphene based Tribo-Sensors for respiratory diagnosis of critical asthma patient

Self-powered ultrafast sensors have received much attention for sustainable operation without any external power source in the Internet of Things (IoT) platform. This paper proposes faster responsive, highly sensitive triboelectric nanogenerator (TENG) sensors based on few layered nitrogen-doped graphene anchored with cobalt nanocluster (Co-N-Gr) to detect the relative concentration of target species, their proximity analysis, and monitor malfunction of human respiration in real-time. Herein, to understand the sensing mechanism, P-type behaviour of this active material is verified under the FET platform by reducing the leakage current density via the implementation of dual dielectric gate (NiO (200 nm)-SiO2 (10 nm)) oxides leading to better control over channel mobility. The device exhibits maximum sensitivity of around 4722 % at zero bias conditions with excellent response and recovery time of 1.16 s and 1.39 s, respectively which falls within the range of standard human breathing frequency. The triboelectric nature of the sensor device at 1 V bias under natural breathing exhibits a high sensitivity (39.56 %) towards relative humidity of 10–90 % with excellent stability over 13 h. In addition, our TENG sensor is highly sensitive towards NOx content upto ppb levelwhich can improve reliability towards asthma detection as NOx content is relatively higher in asthma patients. This approach provides an integrated platform not only towards selective detection of NOx content as well as to identify the individual breathing strength. Furthermore, as-fabricated self-powered device demonstrates its potential in differentiating various respiratory status and has the capability to detect acute exacerbation of chronic obstructive pulmonary disease (AECOPD) via a distinct pattern recognition. Therefore, the work paves the way to design a low-cost flexible device fabrication on Kapton substrate integrable with wearable appliances for commercialization.

Mechanically-flexible wafer-scale integrated-photonics fabrication platform

The field of integrated photonics has advanced rapidly due to wafer-scale fabrication, with integrated-photonics platforms and fabrication processes being demonstrated at both infrared and visible wavelengths. However, these demonstrations have primarily focused on fabrication processes on silicon substrates that result in rigid photonic wafers and chips, which limit the potential application spaces. There are many application areas that would benefit from mechanically-flexible integrated-photonics wafers, such as wearable healthcare monitors and pliable displays. Although there have been demonstrations of mechanically-flexible photonics fabrication, they have been limited to fabrication processes on the individual device or chip scale, which limits scalability. In this paper, we propose, develop, and experimentally characterize the first 300-mm wafer-scale platform and fabrication process that results in mechanically-flexible photonic wafers and chips. First, we develop and describe the 300-mm wafer-scale CMOS-compatible flexible platform and fabrication process. Next, we experimentally demonstrate key optical functionality at visible wavelengths, including chip coupling, waveguide routing, and passive devices. Then, we perform a bend-durability study to characterize the mechanical flexibility of the photonic chips, demonstrating bending a single chip 2000 times down to a bend diameter of 0.5 inch with no degradation in the optical performance. Finally, we experimentally characterize polarization-rotation effects induced by bending the flexible photonic chips. This work will enable the field of integrated photonics to advance into new application areas that require flexible photonic chips.

Green Synthesis of Various Heteroatom‐doped Carbon Quantum Dots from Urine, Whey, and Their Mixture: The Optimization of Synthesis and Potential Applications

AbstractThe employment of biomass waste for the fabrication of carbon quantum dots (CQDs), as a novel fluorescent material with high photoluminescence (PL) activity, has gained intense interest for the last decade. However, the fabrication of CQD from biomass waste encounters challenges including low fluorescence yield, reproducibility, and stability. Therefore, the novel, simple, flexible fabrication routes for CQDs using biomass waste as a precursor are still essential for practical applications. In this study, we reported the employment of human urine (U), sour whey (W), and their mixture (U/W) as precursors for the hydrothermal green synthesis approach. For all cases, CQDs with an excitation‐dependent emission nature were obtained with a quantum yield (QY) value of 48 %, 28 %, and 39 % for U, W, and U/W, respectively. For each case, doping of various heteroatoms such as N, P, S, etc., in the structure of CQDs contributed PL characteristics with high QY, reasonably low cytotoxicity, and, robust pH and storage stability which indicate their high potential in various biomedical applications such as bioimaging and pH sensors. This study proves the utilization of human urine and whey as the precursors for the fabrication of CQDs through a low‐cost, flexible, and eco‐friendly green synthesis procedure.

CNT thin films based on epoxy mixtures: fabrication, electrical characteristics

The simple scaling of silicon transistors no longer ensures the advantages of high energy efficiency, driving research into nanotechnologies beyond silicon. Specifically, digital circuits based on carbon nanotube (CNT) field-effect transistors promise significant advantages in energy efficiency. However, the inability to perfectly control internal nanoscale defects and the variability of carbon nanotubes hinder the realization of very large-scale integrated systems. In this study, we investigated a novel method for fabricating transistors based on carbon nanotubes (CNTs) using epoxy mixtures, obtained the electrical properties of the transistors, and compared their microstructure and composition via the scanning electron microscopy. The carrier mobility on epoxy-based transistors was 28.87 cm²/V∙s, and the transistor switching frequency was 2.2 MHz. The samples exhibited electrical and physical stability over an extended period of time. The use of carbon nanotubes in epoxy resin as a conducting layer for transistors opens significant prospects in the field of electronics. The CNT-epoxy mixture technology allows for more flexible and rapid fabrication of thin-film transistors compared to classical methods. However, it is not appropriate to speak of a complete replacement; in this study, we present an alternative method for producing thin-film transistors, which may be of interest for specific purposes.

Fabrication of a 1×4 optical splitter by 3D printing and microfluidic abrasive micromachining

3D printing has been widely used in the micromachining fields due to its flexibility in design and fabrication. However, due to the presence of undulations on the surface of the finished part, the 3D printing has hardly been employed in the optics manufacturing. In this study, we propose a manufacturing method for optical splitters based on 3D printing and microfluidic abrasive machining. We simulate the effect of microfluidic abrasive machining on microchannels, that helps mitigate the impact of undulations. The 3D printed optical splitter using microfluidic abrasive machining presents high efficiency in optical propagation and high uniformity. We believe that the 3D printing accompanied with microfluidic abrasive micromachining would be a promising technique in the optics manufacturing fields.