Scalable Production Research Articles

Spectral imaging based on custom-made multi-strip filter arrays

Spectral imaging technology based on on-chip spectroscopy can find applications in areas including aerospace, industrial and consumer electronics, and so on. Since each application normally requires a different set and number of spectral bands, the development of customized spectroscopy solutions with more compact size and lower cost becomes quite important. In this paper, we demonstrate a compact, highly customizable imaging spectrometer scheme based on custom-made multi-strip filter arrays, which maintains an average high transmission of ∼85%, narrow bandwidth of ∼30nm, and high optical density of ∼OD2 in the blocking regions across the visible to near-infrared waveband. Spectral imaging experiments are conducted, and the accurate reconstruction of sparse spectral image data is demonstrated as well to prove the validity of the proposed scheme. As a result, the work reported in this paper allows researchers to develop customized spectral imaging equipment in a relatively easy way and also has a great potential to be engineered further for scalable production with a quite low cost.

Advancing into Millimeter Wavelengths for IoT: Multibeam Modified Planar Luneburg Lens Antenna with Porous Plastic Material

This paper introduces an innovative antenna design utilizing a cylindrical dielectric Luneburg lens tailored for 60 GHz Internet of Things (IoT) applications. To optimize V-band communications, the permittivity of the dielectric medium is strategically adjusted by precisely manipulating the physical porosity. In IoT scenarios, employing a microstrip dipole antenna with an emission pattern resembling cos10 enhances beam illumination within the waveguide, thereby improving communication and sensing capabilities. The refractive index gradient of the Luneburg lens is modified by manipulating the material’s porosity using air holes, prioritizing signal accuracy and reliability. Fabricated with polyimide using 3D printing, the proposed antenna features a slim profile ideal for IoT applications with space constraints, such as smart homes and unmanned aerial vehicles. Its innovative design is underscored by selective laser sintering (SLS), offering scalable and cost-effective production. Measured results demonstrate the antenna’s exceptional performance, surpassing IoT deployment standards. This pioneering approach to designing multibeam Luneburg lens antennas, leveraging 3D printing’s porosity control for millimeter-wave applications, represents a significant advancement in antenna technology with scanning ability between −67 and 67 degrees. It paves the way for enhanced IoT infrastructure characterized by advanced sensing capabilities and improved connectivity.

Phosphorus Nitride Imide Nanotubes for Uranium Capture from Seawater.

Nuclear power plays a pivotal role in the global energy supply. The adsorption-based extraction of uranium from seawater is crucial for the rapid advancement of nuclear power. The phosphorus nitride imide (PN) nanotubes were synthesized in this study using a solvothermal method, resulting in chemically stable cross-linked tubular hollow structures that draw inspiration from the intricate snowflake fractal pattern. Detailed characterization showed that these nanotubes possess a uniformly distributed five-coordinated nanopocket, which exhibited great selectivity and efficiency in binding uranium. PN nanotubes captured 97.34% uranium from the low U-spiked natural seawater (∼355 μg L-1) and showed a high adsorption capacity (435.58 mg g-1), along with a distribution coefficient, KdU > 8.71 × 107 mL g-1. In addition, PN nanotubes showed a high adsorption capacity of 7.01 mg g-1 in natural seawater. The facile and scalable production of PN nanotubes presented in this study holds implications for advancing their large-scale implementation in the selective extraction of uranium from seawater.

Scalable protein production by Komagataella phaffii enabled by ARS plasmids and carbon source-based selection

BackgroundMost recombinant Komagataella phaffii (Pichia pastoris) strains for protein production are generated by genomic integration of expression cassettes. The clonal variability in gene copy numbers, integration loci and consequently product titers limit the aptitude for high throughput applications in drug discovery, enzyme engineering or most comparative analyses of genetic elements such as promoters or secretion signals. Circular episomal plasmids with an autonomously replicating sequence (ARS), an alternative which would alleviate some of these limitations, are inherently unstable in K. phaffii. Permanent selection pressure, mostly enabled by antibiotic resistance or auxotrophy markers, is crucial for plasmid maintenance and hardly scalable for production. The establishment and use of extrachromosomal ARS plasmids with key genes of the glycerol metabolism (glycerol kinase 1, GUT1, and triosephosphate isomerase 1, TPI1) as selection markers was investigated to obtain a system with high transformation rates that can be directly used for scalable production processes in lab scale bioreactors.ResultsIn micro-scale deep-well plate experiments, ARS plasmids employing the Ashbya gossypii TEF1 (transcription elongation factor 1) promoter to regulate transcription of the marker gene were found to deliver high transformation efficiencies and the best performances with the reporter protein (CalB, lipase B of Candida antarctica) for both, the GUT1- and TPI1-based, marker systems. The GUT1 marker-bearing strain surpassed the reference strain with integrated expression cassette by 46% upon re-evaluation in shake flask cultures regarding CalB production, while the TPI1 system was slightly less productive compared to the control. In 5 L bioreactor methanol-free fed-batch cultivations, the episomal production system employing the GUT1 marker led to 100% increased CalB activity in the culture supernatant compared to integration construct.ConclusionsFor the first time, a scalable and methanol-independent expression system for recombinant protein production for K. phaffii using episomal expression vectors was demonstrated. Expression of the GUT1 selection marker gene of the new ARS plasmids was refined by employing the TEF1 promoter of A. gossypii. Additionally, the antibiotic-free marker toolbox for K. phaffii was expanded by the TPI1 marker system, which proved to be similarly suited for the use in episomal plasmids as well as integrative expression constructs for the purpose of recombinant protein production.

High Manganese Content of Lipid NanoMn (LNM) by Microfluidic Technology for Enhancing Anti-Tumor Immunity.

Immunotherapy is a clinically effective method for treating tumors. Manganese can activate the cGAS-STING signaling pathway and induce an anti-tumor immune response. However, its efficacy is hindered by non-specific distribution and low uptake rates. In this study, we employed microfluidic technology to design and develop an innovative preparation process, resulting in the creation of a novel manganese lipid nanoparticle (LNM). The lipid manganese nanoparticle produced in this process boasts a high manganese payload, excellent stability, the capacity for large-scale production, and high batch repeatability. LNM has effectively demonstrated the ability to activate the cGAS-STING signaling pathway, induce the production of pro-inflammatory cytokines, and inhibit tumor development. Notably, LNM does not require combination chemotherapy drugs or other immune activators. Therefore, LNM presents a safe, straightforward, and efficient strategy for anti-tumor immune activation, with the potential for scalable production.

Solution-processed 2D van der Waals networks: Fabrication strategies, properties, and scalable device applications

Solution-based processing of two-dimensional (2D) materials has garnered significant interest as a facile and versatile route for the large-scalable production of 2D material films. Despite the benefits in process, these films were not considered suitable for device applications during the early stages of research because their electronic properties were far from those of 2D materials obtained through micromechanical exfoliation or chemical vapor deposition. Due to the small lateral dimensions and polydisperse thickness of constituent 2D nanosheets, the resulting film tends to be porous and exhibits numerous inter-sheet junctions, primarily contacting edge-to-edge. This nanosheet morphology leads to poor electrical conductivity of the network, and also hinders the film functioning as a semiconductor or an insulator. To produce ultrathin 2D nanosheets with narrow thickness distribution and large lateral sizes, various chemical exfoliation strategies have been explored, but these are limited by long process times, involvement of harsh chemicals, and/or undesired structural damage or phase changes. Recent breakthroughs in electrochemical exfoliation using tetraalkylammonium intercalants enabled the production of high-quality 2D nanosheets with structural characteristics favorable for producing ultrathin, conformal films of 2D materials, which allow for scalable production of high-performance electronic components that can readily be assembled into functional devices via solution-processing. In this review article, we aim to offer an extensive introduction solution-based processing techniques for acquiring 2D nanosheets, their subsequent assembly into thin films, and their diverse applications, primarily focusing on electronics and optoelectronics but also extending to other fields. Remaining challenges and potential avenues for advancement will also be discussed.

Bioinspired Polymer Films with Surface Ordered Pyramid Arrays and 3D Hierarchical Pores for Enhanced Passive Radiative Cooling.

Passive radiative cooling (PRC) has been acknowledged to be an environmentally friendly cooling technique, and especially artificial photonic materials with manipulating light-matter interaction ability are more favorable for PRC. However, scalable production of radiative cooling materials with advanced biologically inspired structures, fascinating properties, and high throughput is still challenging. Herein, we reported a bioinspired design combining surface ordered pyramid arrays and internal three-dimensional hierarchical pores for highly efficient PRC based on mimicking natural photonic structures of the white beetle Cyphochilus' wings. The biological photonic film consisting of surface ordered pyramid arrays with a bottom side length of 4 μm together with amounts of internal nano- and micropores was fabricated by using scalable phase separation and a quick hot-pressing process. Optimization of pore structures and surface-enhanced photonic arrays enables the bioinspired film to possess an average solar reflectance of ∼98% and a high infrared emissivity of ∼96%. A temperature drop of ∼8.8 °C below the ambient temperature is recorded in the daytime. Besides the notable PRC capability, the bioinspired film exhibits excellent flexibility, strong mechanical strength, and hydrophobicity; therefore, it can be applied in many complex outdoor scenarios. This work provides a highly efficient and mold replication-like route to develop highly efficient passive cooling devices.

All-solution-processed ultraflexible wearable sensor enabled with universal trilayer structure for organic optoelectronic devices.

All-solution-processed organic optoelectronic devices can enable the large-scale manufacture of ultrathin wearable electronics with integrated diverse functions. However, the complex multilayer-stacking device structure of organic optoelectronics poses challenges for scalable production. Here, we establish all-solution processes to fabricate a wearable, self-powered photoplethysmogram (PPG) sensor. We achieve comparable performance and improved stability compared to complex reference devices with evaporated electrodes by using a trilayer device structure applicable to organic photovoltaics, photodetectors, and light-emitting diodes. The PPG sensor array based on all-solution-processed organic light-emitting diodes and photodetectors can be fabricated on a large-area ultrathin substrate to achieve long storage stability. We integrate it with a large-area, all-solution-processed organic solar module to realize a self-powered health monitoring system. We fabricate high-throughput wearable electronic devices with complex functions on large-area ultrathin substrates based on organic optoelectronics. Our findings can advance the high-throughput manufacture of ultrathin electronic devices integrating complex functions.

Scalable and economical production of oxygen deficient vanadium oxide with tunable vacancies concentration for bendable zinc ion batteries

Although vanadium oxides have high theoretical capacity and low cost, their practical application in aqueous zinc ion batteries (AZIBs) is bottlenecked by sluggish diffusion kinetics and capacity decline. Herein, the oxygen-deficient V2O5-x·nH2O (defined as VOd) with tunable oxygen vacancy concentration has been obtained via an economic and scalable method. The introduction of oxygen vacancies not only provides extra sites for Zn2+ storage, but also reduces the electrostatic barrier for Zn2+ intercalation, resulting in enhanced capacity and cycling stability. As a result, VOd cathode with proper amount of oxygen defect exhibits a high capacity of 415 mAh g−1 and energy density of 294 Wh kg−1 at 0.2 A g−1, estimating a roughly chemical costs of $64/kWH for VOd cathode. Besides, the VOd exhibits excellent stability at 20 A g−1 with average capacity decay of 0.004 % per cycle for 5000 cycles. Moreover, the bendable quasi-solid VOd//Zn battery maintains stable capacity of 200 mAh g−1 at 2 A g−1 even when repeatedly bending to straight angles. Therefore, the economical production of VOd cathode and construction of bendable quasi-solid battery provides a feasible way to boost the construction of efficient flexible energy storage devices and broadened application of AZIBs.

Revolutionizing Infection Control: Harnessing MXene-Based Nanostructures for Versatile Antimicrobial Strategies and Healthcare Advancements.

The escalating global health challenge posed by infections prompts the exploration of innovative solutions utilizing MXene-based nanostructures. Societally, the need for effective antimicrobial strategies is crucial for public health, while scientifically, MXenes present promising properties for therapeutic applications, necessitating scalable production and comprehensive characterization techniques. Here we review the versatile physicochemical properties of MXene materials for combatting microbial threats and their various synthesis methods, including etching and top-down or bottom-up techniques. Crucial characterization techniques such as XRD, Raman spectroscopy, SEM/TEM, FTIR, XPS, and BET analysis provide insightful structural and functional attributes. The review highlights MXenes' diverse antimicrobial mechanisms, spanning membrane disruption and oxidative stress induction, demonstrating efficacy against bacterial, viral, and fungal infections. Despite translational hurdles, MXene-based nanostructures offer broad-spectrum antimicrobial potential, with applications in drug delivery and diagnostics, presenting a promising path for advancing infection control in global healthcare.

Superior supercapacitor performance with tuneable 2D/3D morphological microporous carbons of zeolitic imidazolate frameworks synthesized by recycling mother liquors

Carbonized metal–organic frameworks (MOFs)-based nanoporous carbon materials (NPCs) offer attractive activities in electrochemical energy conversion and storage (EECS) applications; however, there is the need for scalable MOFs production under reduced energy/environmental impact. This study reports a green synthesis route for model zeolitic imidazolate framework (ZIF-8) materials via recycling methanol-based mother liquors (ZIF-RMLx) under room temperature stirring and their carbonized materials (CZC-RMLx) for high-performance supercapacitors. Series of ZIF-RMLx samples produced in four recycles offer rod-/sheet-/polyhedral-like 2D/3D microstructures with tuneable internal and external framework and morphological features. Accordingly, CZC-RMLx, obtained by direct pyrolysis, with high microporosity and surface area of 1500 m2 g−1 deliver excellent capacitance values of 200–340 F g−1, compared to typical MOFs-derived or chemically activated/templated NPCs, produced via extended chemical processing. Structure-relevant and comparative performance analysis reveal insights for improved charge storage and carbonization-dependent graphitization, nitrogen-doping and microporosity-controlled capacitance characteristics in the CZC-RMLx over typical NPCs in literature. The device-level performance with a long-term durability over 21,000 cycles is demonstrated. The practical potential of CZC-RMLx is further evaluated by fabricating solid-state cells and their parallel and series circuit combinations result in overall capacitance and voltage boost to 450 F g−1 and 2.4 V, respectively.

In Situ Engineering Multifunctional Active Sites of Ruthenium-Nickel Alloys for pH-Universal Ampere-Level Current-Density Hydrogen Evolution.

Developing robust non-platinum electrocatalysts with multifunctional active sites for pH-universal hydrogen evolution reaction (HER) is crucial for scalable hydrogen production through electrochemical water splitting. Here ultra-small ruthenium-nickel alloy nanoparticles steadily anchored on reduced graphene oxide papers (Ru-Ni/rGOPs) as versatile electrocatalytic materials for acidic and alkaline HER are reported. These Ru-Ni alloy nanoparticles serve as pH self-adaptive electroactive species by making use of in situ surface reconstruction, where surface Ni atoms are hydroxylated to produce bifunctional active sites of Ru-Ni(OH)2 for alkaline HER, and selectively etched to form monometallic Ru active sites for acidic HER, respectively. Owing to the presence of Ru-Ni(OH)2 multi-site surface, which not only accelerates water dissociation to generate reactive hydrogen intermediates but also facilitates their recombination into hydrogen molecules, the self-supported Ru90Ni10/rGOP hybrid electrode only takes overpotential of as low as ≈106mV to deliver current density of 1000mAcm-2, and maintains exceptional stability for over 1000h in 1 m KOH. While in 0.5 m H2SO4, the Ru90Ni10/rGOP hybrid electrode exhibits acidic HER catalytic behavior comparable to commercially available Pt/C catalyst due to the formation of monometallic Ru shell. These electrochemical behaviors outperform some of the best Ru-based catalysts and make it attractive alternative to Pt-based catalysts toward highly efficient HER.

Few-layer graphene production through graphite exfoliation in pressurized CO2 assisted by natural surfactant

Graphene research has captivated researchers worldwide, propelling innovation across diverse industries. Through the liquid-phase exfoliation methodology of graphite powder, we have demonstrated a rapid route for obtaining few-layer and multi-layer graphene using a natural surfactant, cardanol. Aqueous phase exfoliation of graphite in the presence of cardanol as a surfactant was conducted to obtain pre-exfoliated graphite suspensions. The influence of different ultrasonication times, 10, 20, and 30 min, and contact times with the surfactant, 1 and 60 min, on the stability and concentration of dispersed exfoliated graphite was evaluated. Results indicate that ultrasonication for 20 min resulted in improved stability and reduced graphene flake sizes, making it suitable for scalable graphene production. Subsequently, the most stable dispersions of exfoliated graphite were subjected to CO2-pressurized treatment. Promising results were obtained when employing cardanol at its critical micelle concentration. The graphene exhibited good structural quality, low defect density, and small stacking, with an average size of 15 nm, where 40 % of the stacked graphene was smaller than 5 nm. The findings provide valuable recommendations for the scalable production of graphene with multilayers and a few layers (FLG/MLG), using cardanol, a friendly surfactant, and a novel method of exfoliation utilizing supercritical CO2. This technology represents an innovative approach, with potential applications in supercapacitors, solar cells, biosensors, polymer composites, and advanced materials.

Lab-on-PCB technology for liquid monopropellant microthrusters: Design, fabrication, and performance evaluation

In this study, we introduce an innovative approach to developing microthrusters for nanosatellites using lab-on-printed circuit board (PCB) technology. Focusing on the challenges in nanosatellite propulsion, we design and fabricate microthrusters in horizontal and vertical configurations. These thrusters are constructed utilizing standardized PCB processes, including stencil printing and soldering. Our propulsion tests assess the performance of these microthrusters, focusing on thermal and C* efficiencies, thrust efficiency, and nozzle throat durability. The results demonstrate the effective decomposition of hydrogen peroxide and heat retention in the MnOx/Al2O3-loaded PCB catalyst chambers for both types of thrusters. The lab-on-PCB technology presents potential for scalable, durable, and efficient production of microthruster modules. We also propose a modular assembly approach, allowing for the customization of propulsion systems tailored to specific satellite missions. Future directions include exploring integration with satellite systems and conducting dynamic control performance testing, positioning lab-on-PCB technology as a versatile solution for the evolving requirements of nanosatellite constellations.

Sustainable and cyclic synthesis of 2D Co(OH)2 nanosheets for scalable production of high-performance electrocatalysts

Ultrathin 2D nanomaterials with extremely large surface area and unique electrochemical properties are considered excellent electrocatalyst candidates for clean energy conversion and environmental applications. However, it is still challenging to prepare 2D catalysts through a scalable and sustainable process that may become suitable for industrial demands. Here, we reported a facile cyclic synthesis method of ultrathin 2D nanomaterials based on the ionic layer epitaxy. By repeatedly refreshing a surfactant monolayer on the solution surface, free-standing 2.2 nm thick hexagonal Co(OH)2 nanosheets were obtained from the water surface at ambient conditions in multiple cycles. These nanosheets exhibited a consistently high OER performance with an average overpotential of 427.4 ± 5.3 mV at 10 mA cm−2. Remarkably, hexagonal NSs could be obtained from a wide range of precursor concentrations which could enable over 84 cycles of synthesis on the same stock precursor solution. It will shed light on the design of autonomous and sustainable synthesis of 2D nanomaterials for advanced electrocatalysis development toward a clean future.

Continuous production of ultratough semiconducting polymer fibers with high electronic performance.

Conjugated polymers have demonstrated promising optoelectronic properties, but their brittleness and poor mechanical characteristics have hindered their fabrication into durable fibers and textiles. Here, we report a universal approach to continuously producing highly strong, ultratough conjugated polymer fibers using a flow-enhanced crystallization (FLEX) method. These fibers exhibit one order of magnitude higher tensile strength (>200 megapascals) and toughness (>80 megajoules per cubic meter) than traditional semiconducting polymer fibers and films, outperforming many synthetic fibers, ready for scalable production. These fibers also exhibit unique strain-enhanced electronic properties and exceptional performance when used as stretchable conductors, thermoelectrics, transistors, and sensors. This work not only highlights the influence of fluid mechanical effects on the crystallization and mechanical properties of conjugated polymers but also opens up exciting possibilities for integrating these functional fibers into wearable electronics.

Sputtering Deposition of ZnO Thin Films for Photocatalytic Hydrogen Production: Perspectives on Upscaling

This study presents the successful implementation of ZnO thin films (denoted as z01, z02, and z03) through magnetron sputtering in the photocatalytic production of hydrogen using a low-intensity UV source (3 mW cm−2). The one-step synthesis process demonstrates simplicity and scalability. The deposited coatings, with thicknesses ranging from 62 to 209 nm, exhibit a hexagonal crystalline structure and display visible luminescence in the yellow-red range, attributed to point defects in the ZnO lattice. Among the samples, z03 (62 nm in thickness) exhibited the most promising performance in photocatalytic hydrogen production, achieving a rate of (5387.2 ± 151.6) µmol g⁻¹ h⁻¹ when utilizing methanol as a hole scavenger. These findings hold great potential for upscaling such coatings in energy harvesting applications. The present work opens new avenues for efficient and scalable hydrogen production, contributing to improving clean energy technologies.

Synthesis of 2D Phosphorene: Current Status and Challenges

AbstractPhosphorene, a 2D(two‐dimensional) material, holds immense promise in various applications due to its unique properties. Here, a comprehensive overview of their recent synthesis progresses, with a specific focus on three phosphorene varieties: black phosphorene, blue phosphorene, and violet phosphorene is provided. Black phosphorene, given its versatile properties, is extensively studied, but the challenges persist in achieving scalable production with high quality and controllable thicknesses. The synthesis of blue phosphorene involves epitaxial methods but results in relatively small structures, limiting its practical applications. Notably, the successful synthesis of violet phosphorene remains limited, achieved only through mechanical and liquid‐phase exfoliation (LPE) methods. Despite significant progression in phosphorene synthesis, a critical need is emphasized for a cost‐effective and easily controllable method capable of efficiently managing the thickness of phosphorene. The challenges, such as scalability issues and the presence of impurities, highlight the complexity of phosphorene preparation methods. The review emphasizes the importance of continued scientific engagement to overcome these obstacles and advance the research topic. In essence, while phosphorene shows great potential, unlocking its full range of applications requires further research and innovation in synthesis methodologies.

Monolithically integrated micro-supercapacitors with high areal number density produced by surface adhesive-directed electrolyte assembly

Accurately placing very small amounts of electrolyte on tiny micro-supercapacitors (MSCs) arrays in close proximity is a major challenge. This difficulty hinders the development of densely-compact monolithically integrated MSCs (MIMSCs). To overcome this grand challenge, we demonstrate a controllable electrolyte directed assembly strategy for precise isolation of densely-packed MSCs at micron scale, achieving scalable production of MIMSCs with ultrahigh areal number density and output voltage. We fabricate a patterned adhesive surface across MIMSCs, that induce electrolyte directed assembly on 10,000 highly adhesive MSC regions, achieving a 100 µm-scale spatial separation between each electrolyte droplet within seconds. The resultant MIMSCs achieve an areal number density of 210 cells cm−2 and a high areal voltage of 555 V cm−2. Further, cycling the MIMSCs at 190 V over 9000 times manifests no performance degradation. A seamlessly integrated system of ultracompact wirelessly-chargeable MIMSCs is also demonstrated to show its practicality and versatile applicability.

Computational synthesis of a new generation of 2D-based perovskite quantum materials

Perovskite-based optoelectronic devices have emerged as a promising energy source due to their potential for scalable production. This study introduces “perovskene,” a novel class of 2D materials derived from the ABC3-like perovskites, synthesized via a data-driven, high-throughput computational strategy. We harness machine learning and multitarget deep neural networks to systematically investigate the structure–property relations, paving the way for targeted material design and optimization in fields such as renewable energy, electronics, and catalysis. The characterization of over 1500 synthesized structures shows that more than 500 structures are stable, revealing properties such as ultra-low work function and large magnetic moment, underscoring the potential for advanced technological applications.