3D Printing Thermally Stable High-Performance Polymers Based on a Dual Curing Mechanism

High-performance polymers are an important class of materials that are used in challenging conditions, such as in aerospace applications. Until now, 3D printing based on stereolithography processes can not be performed due to a lack of suitable materials. There is report on new materials and printing compositions that enable 3D printing of objects having extremely high thermal resistance, with Tg of 283 °C and excellent mechanical properties. The printing is performed by a low-cost Digital Light Processing printer, and the formulation is based on a dual-cure mechanism, photo, and thermal process. The main components are a molecule that has both epoxy and acrylate groups, alkylated melamine that enables a high degree of crosslinking, and a soluble precursor of silica. The resulting objects are made of hybrid materials, in which the silicon is present in the polymeric backbone and partly as silica enforcement particles.     

Formation Theory and Printability of Photocurable Hydrogel for 3D Bioprinting

Bio-ink has gradually transited from ionic-crosslinking to photocrosslinking due to photocurable bio-hydrogel having good formability and biocompatibility. It is very important to understand and quantify the crosslinking process of photocurable hydrogels, otherwise, bioprinting cannot be standardized and scalable. However, there are few studies on hydrogel formation process and its photocrosslinking behavior which cannot be accurately predicted. Herein, the photoinitiated radical polymerized bio-hydrogels are taken as an example to establish the formation theory. Three typical crosslinking reactions are first distinguished. It is further proposed that not all double-bonds consumed during crosslinking contributeequally to polymerization. Then the concept of effective double-bond conversion (EDBC) is elicited. Deriving from EDBC, several important formation indices are defined. According to theory, it is predicted that slow crosslinking can improve the crosslinking degree. Furthermore, based on the slow crosslinking effect, a new strategy of projection-based 3D printing (PBP) is proposed, which significantly improved printing quality and efficiency. Overall, this work will fill the gap in hydrogel's formation theory, making it possible to accurately quantify the formation process.     

Enabling On-Demand Conformal Zn-Ion Batteries on Non-Developable Surfaces

Conventional power sources encounter difficulties in achieving structural unitization with complex-shaped electronic devices because of their fixed form factors. Here, it is realized that an on-demand conformal Zn-ion battery (ZIB) on non-developable surfaces uses direct ink writing (DIW)-based nonplanar 3D printing. First, ZIB component (manganese oxide-based cathode, Zn powder-based anode, and UV-curable gel composite electrolyte) inks are designed to regulate their colloidal interactions to fulfill the rheological requirements of nonplanar 3D printing, and establish bi-percolating ion/electron conduction pathways, thereby enabling geometrical synchronization with non-developable surfaces, and ensuring reliable electrochemical performance. The ZIB component inks are conformally printed on arbitrary curvilinear substrates to produce embodied ZIBs that can be seamlessly integrated with complicated 3D objects (including human ears). The conformal ZIB exhibits a high fill factor (i.e., areal coverage of cells on underlying substrates, ≈100%) that ensures high volumetric energy density (50.5 mWh cm_cell⁻³), which exceeds those of previously-reported shape-adaptable power sources.     

3D Printable One-Part Carbon Nanotube-Elastomer Ink for Health Monitoring Applications

3D printing of conductive elastomers is a promising route to personalized health monitoring applications due to its flexibility and biocompatibility. Here, a one-part, highly conductive, flexible, stretchable, 3D printable carbon nanotube (CNT)-silicone composite is developed and thoroughly characterized. The one-part nature of the inks: i) enables printing without prior mixing and cures under ambient conditions; ii) allows direct dispensing at ≈100 µm resolution printability on nonpolar and polar substrates; iii) forms both self-supporting and high-aspect-ratio structures, key aspects in additive biomanufacturing that eliminate the need for sacrificial layers; and iv) lends efficient, reproducible, and highly sensitive responses to various tensile and compressive stimuli. The high electrical and thermal conductivity of the CNT-silicone composite is further extended to facilitate use as a flexible and stretchable heating element, with applications in body temperature regulation, water distillation, and dual temperature sensing and Joule heating. Overall, the facile fabrication of this composite points to excellent synergy with direct ink writing and can be used to prepare patient-specific wearable electronics for motion detection and cardiac and respiratory monitoring devices and toward advanced personal health tracking and bionic skin applications.     

Tough Transient Ionic Junctions Printed with Ionic Microgels

Emerging soft ionotronics better match the human body mechanically and electrically compared to conventional rigid electronics. They hold great potential for human-machine interfaces, wearable and implantable devices, and soft machines. Among various ionotronic devices, ionic junctions play critical roles in rectifying currents as electrical p–n junctions. Existing ionic junctions, however, are limited in electrical and mechanical performance, and are difficult to fabricate and degrade. Herein, the design, fabrication, and characterization of tough transient ionic junctions fabricated via 3D ionic microgel printing is reported. The 3D printing method demonstrates excellent printability and allows one to fabricate ionic junctions of various configurations with high fidelity. By combining ionic microgels, degradable networks, and highly charged biopolymers, the ionic junctions feature high stretchability (stretch limit 27), high fracture energy (>1000 Jm⁻²), excellent electrical performance (current rectification ratio >100), and transient stability (degrade in 1 week). A variety of ionotronic devices, including ionic diodes, ionic bipolar junction transistors, ionic full-wave rectifiers, and ionic touchpads are further demonstrated. This study merges ionotronics, 3D printing, and degradable hydrogels, and will motivate the future development of high-performance transient ionotronics.     

MXene Functionalized,Highly Breathable and Sensitive Pressure Sensors with Multi-Layered Porous Structure

Breathable, flexible, and highly sensitive pressure sensors have drawn increasing attention due to their potential in wearable electronics for body-motion monitoring, human-machine interfaces, etc. However, current pressure sensors are usually assembled with polymer substrates or encapsulation layers, thus causing discomfort during wearing (i.e., low air/vapor permeability, mechanical mismatch) and restricting their applications. A breathable and flexible pressure sensor is reported with nonwoven fabrics as both the electrode (printed with MXene interdigitated electrode) and sensing (coated with MXene/silver nanowires) layers via a scalable screen-printing approach. Benefiting from the multi-layered porous structure, the sensor demonstrates good air permeability with high sensitivity (770.86–1434.89 kPa⁻¹), a wide sensing range (0–100 kPa), fast response/recovery time (70/81 ms), and low detection limit (≈1 Pa). Particularly, this sensor can detect full-scale human motion (i.e., small-scale pulse beating and large-scale walking/running) with high sensitivity, excellent cycling stability, and puncture resistance. Additionally, the sensing layer of the pressure sensor also displays superior sensitivity to humidity changes, which is verified by successfully monitoring human breathing and spoken words while wearing a sensor-embedded mask. Given the outstanding features, this breathable sensor shows promise in the wearable electronic field for body health monitoring, sports activity detection, and disease diagnosis.     

Solid Ink Laser Patterning for High-Resolution Information Labels with Supervised Learning Readout

Tagging, tracking, or validation of products are often facilitated by inkjet-printed optical information labels. However, this requires thorough substrate pretreatment, ink optimization, and often lacks in printing precision/resolution. Herein, a printing method based on laser-driven deposition of solid polymer ink that allows for printing on various substrates without pretreatment is demonstrated. Since the deposition process has a precision of <1 µm, it can introduce the concept of sub-positions with overlapping spots. This enables high-resolution fluorescent labels with comparable spot-to-spot distance of down to 15 µm (444,444 spots cm⁻²) and rapid machine learning-supported readout based on low-resolution fluorescence imaging. Furthermore, the defined thickness of the printed polymer ink spots can be used to fabricate multi-channel information labels. Additional information can be stored in different fluorescence channels or in a hidden topography channel of the label that is independent of the fluorescence.     

In Situ Electrical Network Activation and Deactivation in Short Carbon Fiber Composites via 3D Printing

Prior studies on carbon-filler based, conductive polymer composites have mainly investigated how conductive filler morphology and concentration can tailor a material's electrical conductivity and overlooks the effects of filler alignment due to the difficulty to control and quickly quantify the filler alignment. Here, direct ink write 3D printing's unique ability is utilized to control carbon fiber alignment with a single process parameter, velocity ratio, to instantaneously activate or deactivate the electrical network in composites. Maximum electrical conductivity is achieved by randomly aligning carbon fibers that enhances the chance of direct fiber-to-fiber contact and, thus, activating the electrical network. However, aligning the fibers by increasing the velocity ratio disrupts the electrical network by minimizing fiber-to-fiber contact that resulted in a drastic decrease in electrical conductivity by as much as five orders of magnitude in both short and long carbon fiber composites. With this study, this study demonstrates that electrically conductive or insulative composites can be fabricated sequentially with a single ink. This novel ability to instantaneously control the electrical conductivity of carbon fiber reinforced composites allow to directly embed conductive pathways into designs to 3D print multifunctional composites that are capable of localized heating and self-sensing.     

用于超外差接收机提供本振源的高功率510 GHz单片集成三倍频器

本文介绍了一种基于砷化镓材料的高功率490~530 GHz单片集成三倍频器。基于提出的对称平衡结构,该三倍频器不仅可以实现良好的振幅和相位平衡,用来实现高效的功率合成,还可以在没有任何旁路电容的情况下提供直流偏置路径以保证高效倍频效率。同时,开展容差性仿真分析二极管关键电气参数与结构参数对倍频性能的影响研究,以便最大化提升倍频性能。最终,在大约80~200 mW的输入功率驱动下,研制的510 GHz三倍频,在490~530 GHz频率范围内,输出功率为4~16 mW,其中峰值倍频效率11%。在522 GHz频点处,该三倍频在218 mW的输入功率驱动下,产生16 mW的最大输出功率。该三倍频器后期将用于1 THz的固态外超外差混频器的本振源。     

一种高效的大功率宽带整流电路

提出了一种由π型匹配枝节、整流二极管、直通滤波器组成的高效大功率宽带整流电路。采用2只HSMS-282P肖特基二极管桥设计单级倍压整流电路,使电路在整流效率不下降的情况下提升输入的功率容量;采用π型匹配枝节实现阻抗匹配,使电路具有宽频特性,同时其并联短路枝节可以作为输入滤波器,实现小型化和整流效率的提高。直通滤波器用于抑制基频和二极管非线性产生的高次谐波,以提高整流效率。实测结果表示：在2.05~2.6 GHz带宽内整流效率大于60%;在2.45 GHz工作频率和35 dBm输入功率下,整流电路在330 Ω负载上获得70%的整流效率。该整流电路具有整流效率高、功率容量大、频带宽的特性,可为工程人员设计大功率微波整流电路提供设计指导。