Photocurable liquid core-fugitive shell printing of optical waveguides

Toward Multiscale, Multimaterial 3D Printing

Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.

Biohybrid Photonic Platform for Subcellular Stimulation and Readout of In Vitro Neurons

Targeted manipulation of neural activity via light has become an indispensable tool for gaining insights into the intricate processes governing single neurons and complex neural networks. To shed light onto the underlying interaction mechanisms, it is crucial to achieve precise control of individual neural activity, as well as a spatial read-out resolution on the nanoscale. Here, a versatile photonic platform with subcellular resolution for stimulation and monitoring of in-vitro neurons is demonstrated. Low-loss photonic waveguides are fabricated on glass substrates using nanoimprint lithography and featuring a loss of only -0.9 ± 0.2 dB cm-1 at 489 nm and are combined with optical fiber-based waveguide-access and backside total internal reflection fluorescence microscopy. Neurons are grown on the bio-functionalized photonic chip surface and, expressing the light-sensitive ion channel Channelrhodopsin-2, are stimulated within the evanescent field penetration depth of 57 nm of the biocompatible waveguides. The versatility and cost-efficiency of the platform, along with the possible subcellular resolution, enable tailor-made investigations of neural interaction dynamics with defined spatial control and high throughput.

Direct ink writing 3D-printed optical waveguides for multi-layer interconnect

Low-cost, short-range optical interconnect technology plays an indispensable role in high-speed board-level data communications. In general, 3D printing technology can easily and quickly produce optical components with free-form shapes, while the traditional manufacturing process is complicated and time-consuming. Here, we present a direct ink writing 3D-printing technology to fabricate optical waveguides for optical interconnects. The waveguide core is 3D printed optical polymethylmethacrylate (PMMA) polymer, with propagation loss of 0.21 dB/cm at 980 nm, 0.42 dB/cm at 1310 nm, and 1.08 dB/cm at 1550 nm, respectively. Furthermore, a high-density multilayer waveguide arrays, including a four-layer waveguide arrays with a total of 144 waveguide channels, is demonstrated. Error-free data transmission at 30 Gb/s is achieved for each waveguide channel, indicating that the printing method can produce optical waveguides with excellent optical transmission performance. We believe this simple, low-cost, highly flexible, and environmentally friendly method has great potential for high-speed short-range optical interconnects.

Fabrication and Functionality Integration Technologies for Small-Scale Soft Robots

Small-scale soft robots are attracting increasing interest for visible and potential applications owing to their safety and tolerance resulting from their intrinsic soft bodies or compliant structures. However, it is not sufficient that the soft bodies merely provide support or system protection. More importantly, to meet the increasing demands of controllable operation and real-time feedback in unstructured/complicated scenarios, these robots are required to perform simplex and multimodal functionalities for sensing, communicating, and interacting with external environments during large or dynamic deformation with the risk of mismatch or delamination. Challenges are encountered during fabrication and integration, including the selection and fabrication of composite/materials and structures, integration of active/passive functional modules with robust interfaces, particularly with highly deformable soft/stretchable bodies. Here, methods and strategies of fabricating structural soft bodies and integrating them with functional modules for developing small-scale soft robots are investigated. Utilizing templating, 3D printing, transfer printing, and swelling, small-scale soft robots can be endowed with several perceptual capabilities corresponding to diverse stimulus, such as light, heat, magnetism, and force. The integration of sensing and functionalities effectively enhances the agility, adaptability, and universality of soft robots when applied in various fields, including smart manufacturing, medical surgery, biomimetics, and other interdisciplinary sciences.

Continuous resin refilling and hydrogen bond synergistically assisted 3D structural color printing

3D photonic crystals (PCs) have attracted extensive attention due to their unique optical properties. However, fabricating 3D PCs structure by 3D printing colloidal particles is limited by control of assembly under a fast-printing speed. Here, we employ continuous digital light processing (DLP) 3D printing strategy with hydrogen bonds assisted colloidal inks for fabricating well-assembled 3D PCs structures. Stable dispersion of colloidal particles inside UV-curable system induced by hydrogen bonding and suction force induced by continuous curing manner cooperatively realize the simultaneous macroscopic printing and microscopic particle assembly, which endows volumetric color property. Structural color can be well regulated by controlling the particle diameter and printing speed, through which various complex 3D structures with desired structural color distribution and optical light-guide properties are acquired. This 3D color construction approach shows great potential in customized jewelry accessories, decoration and optical device preparation, and will innovate the development of structural color.

Embedded Core-Shell 3D Printing (eCS3DP) with Low-Viscosity Polysiloxanes

Flexible core-shell 3D structures are essential for the development of soft sensors and actuators. Despite recent advancements in 3D printing, the fabrication of flexible 3D objects with internal architectures (such as channels and void spaces) remains challenging with liquid precursors due to the difficulty to maintain the printed structures. The difficulty of such fabrication is prominent especially when low-viscosity polysiloxane resins are used. This study presents a unique approach to applying direct ink writing (DIW) 3D printing in a three-phase system to overcome this limitation. We performed core-shell 3D printing using a low-viscosity commercial polysiloxane resin (Ecoflex 10) as shell inks combined with a coaxially extruded core liquid (Pluronic F127) in Bingham plastic microparticulate gels (ethanol gel). In the process termed embedded core-shell 3D printing (eCS3DP), we highlighted the dependence of the rheological characteristics of the three fluids on the stability of the printed core-shell filament. With the core liquid with a sufficiently high concentration of Pluronic F127 (30 w/w%; σ_y = 158.5 Pa), the interfacial instability between the shell liquid and core liquid was suppressed; the removal of the core liquid permitted the fabrication of perfusable channels. We identified the printing conditions to ensure lateral attachments of printed core-shell filaments. Interestingly, judicious selection of the rheological properties and flow rates of three phases allowed the formation of droplets consisting of core liquids distributed along the printed filaments. eCS3DP offers a simple route to fabricate 3D structures of a soft elastomeric matrix with embedded channels and should serve as a useful tool for DIW-based fabrication of flexible wearable devices and soft robotic components.

Direct Ink Writing: A 3D Printing Technology for Diverse Materials

Additive manufacturing (AM) has gained significant attention due to its ability to drive technological development as a sustainable, flexible, and customizable manufacturing scheme. Among the various AM techniques, direct ink writing (DIW) has emerged as the most versatile 3D printing technique for the broadest range of materials. DIW allows printing of practically any material, as long as the precursor ink can be engineered to demonstrate appropriate rheological behavior. This technique acts as a unique pathway to introduce design freedom, multifunctionality, and stability simultaneously into its printed structures. Here, a comprehensive review of DIW of complex 3D structures from various materials, including polymers, ceramics, glass, cement, graphene, metals, and their combinations through multimaterial printing is presented. The review begins with an overview of the fundamentals of ink rheology, followed by an in-depth discussion of the various methods to tailor the ink for DIW of different classes of materials. Then, the diverse applications of DIW ranging from electronics to food to biomedical industries are discussed. Finally, the current challenges and limitations of this technique are highlighted, followed by its prospects as a guideline toward possible futuristic innovations.

Microfluidics-enabled functional 3D printing

Microfluidic technology has established itself as a powerful tool to enable highly precise spatiotemporal control over fluid streams for mixing, separations, biochemical reactions, and material synthesis. 3D printing technologies such as extrusion-based printing, inkjet, and stereolithography share similar length scales and fundamentals of fluid handling with microfluidics. The advanced fluidic manipulation capabilities afforded by microfluidics can thus be potentially leveraged to enhance the performance of existing 3D printing technologies or even develop new approaches to additive manufacturing. This review discusses recent developments in integrating microfluidic elements with several well-established 3D printing technologies, highlighting the trend of using microfluidic approaches to achieve functional and multimaterial 3D printing as well as to identify potential future research directions in this emergent area.

Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses

3D printing has been considered as a sustainable method to construct complicated 3D structures. However, the step effect induced by the traditional point-by-point or layer-by-layer additive manufacturing mode inevitably occurs and remains an obstacle to realizing the smoothness and uniformity of 3D samples. Here, a continuous liquid film confined 3D printing strategy is proposed to fabricate high-precision 3D structures based on the Digital Light Processing (DLP) technology. With the control of the confinement of the liquid-solid interface and the continuous printing mode, liquid film adhering to the cured structure is sucked into the cured layer structures with excess resin adhering to the cured structure scraping off, where the step effect is eliminated and post-washing is avoided. The morphology and dimension of the confined liquid film can be well regulated by ink properties and printing parameters to optimize the surface smoothness and printing fidelity. In addition, heat accumulation and thermal diffusion are also suppressed, ensuring the long-term printing stability. A centimeter-scale contact lens structure with central thickness of ≈135 µm comparable to commercial ones can be printed, which possesses extreme smoothness (sub 1.3 nm), homogeneous mechanical characteristic, biocompatibility, and high optical properties with imaging resolution of up to 228.1 lp mm^-1 .

Patient-Specific Bone Particles Bioprinting for Bone Tissue Engineering

Although bioinks with both high printability and shape fidelity while maintaining high cell viability are developed, the biofunctionality of the resulting bioprinted construct is often overlooked. To address this, a methacrylated gelatin (GelMA)-based bioink biofunctionalized with bone particles (BPs) is developed as a personalized treatment strategy for bone regeneration. The bioink consists of incorporating BPs of various sizes (0-500 µm) in GelMA at various concentrations (ranging from 5 to 15% w/v). The printability of the bioink is systematically investigated and it is demonstrated that a 15% w/v BP-loading results in high print quality for 10% and 12.5% GelMA concentrations. Rheological evaluation reveals a strong shear thinning behavior essential for printing and a high gel strength in bioink with 15% w/v 0-500 µm BPs for both GelMA concentrations. In addition, the printability of the bioink and the metabolic activity of the resulting scaffolds are dependent on both the concentration of hydrogel and size of the BPs. Importantly, the cells initially contained in the BPs are able to migrate and colonize the bioprinted scaffold while maintaining their capacity to express early osteogenic markers. This study demonstrates the feasibility of bioprinted viable BPs and may have some potential for chairside clinical translation.

Integrated dynamic wet spinning of core-sheath hydrogel fibers for optical-to-brain/tissue communications

Hydrogel optical light-guides have received substantial interest for applications such as deep-tissue biosensors, optogenetic stimulation and photomedicine due to their biocompatibility, (micro)structure control and tissue-like Young's modulus. However, despite recent developments, large-scale fabrication with a continuous synthetic methodology, which could produce core-sheath hydrogel fibers with the desired optical and mechanical properties suitable for deep-tissue applications, has yet to be achieved. In this study, we report a versatile concept of integrated light-triggered dynamic wet spinning capable of continuously producing core-sheath hydrogel optical fibers with tunable fiber diameters, and mechanical and optical propagation properties. Furthermore, this concept also exhibited versatility for various kinds of core-sheath functional fibers. The wet spinning synthetic procedure and fabrication process were optimized with the rational design of the core/sheath material interface compatibility [core = poly(ethylene glycol diacrylate-co-acrylamide); sheath = Ca-alginate], optical transparency, refractive index and spinning solution viscosity. The resulting hydrogel optical fibers exhibited desirable low optical attenuation (0.18 ± 0.01 dB cm⁻¹ with 650 nm laser light), excellent biocompatibility and tissue-like Young's modulus (<2.60 MPa). The optical waveguide hydrogel fibers were successfully employed for deep-tissue cancer therapy and brain optogenetic stimulation, confirming that they could serve as an efficient versatile tool for diverse deep-tissue therapy and brain optogenetic applications.

Control-Based 4D Printing: Adaptive 4D-Printed Systems

Building on the recent progress of four-dimensional (4D) printing to produce dynamic structures, this study aimed to bring this technology to the next level by introducing control-based 4D printing to develop adaptive 4D-printed systems with highly versatile multi-disciplinary applications, including medicine, in the form of assisted soft robots, smart textiles as wearable electronics and other industries such as agriculture and microfluidics. This study introduced and analysed adaptive 4D-printed systems with an advanced manufacturing approach for developing stimuli-responsive constructs that organically adapted to environmental dynamic situations and uncertainties as nature does. The adaptive 4D-printed systems incorporated synergic integration of three-dimensional (3D)-printed sensors into 4D-printing and control units, which could be assembled and programmed to transform their shapes based on the assigned tasks and environmental stimuli. This paper demonstrates the adaptivity of these systems via a combination of proprioceptive sensory feedback, modeling and controllers, as well as the challenges and future opportunities they present.

Additive Manufacturing: Applications and Directions in Photonics and Optoelectronics

The combination of materials with targeted optical properties and of complex, 3D architectures, which can be nowadays obtained by additive manufacturing, opens unprecedented opportunities for developing new integrated systems in photonics and optoelectronics. The recent progress in additive technologies for processing optical materials is here presented, with emphasis on accessible geometries, achievable spatial resolution, and requirements for printable optical materials. Relevant examples of photonic and optoelectronic devices fabricated by 3D printing are shown, which include light-emitting diodes, lasers, waveguides, optical sensors, photonic crystals and metamaterials, and micro-optical components. The potential of additive manufacturing applied to photonics and optoelectronics is enormous, and the field is still in its infancy. Future directions for research include the development of fully printable optical and architected materials, of effective and versatile platforms for multimaterial processing, and of high-throughput 3D printing technologies that can concomitantly reach high resolution and large working volumes.

Three-Dimensional Printed Photoluminescent Polymeric Waveguides

In this work, we propose an innovative strategy for obtaining functional objects employing a light-activated three-dimensional (3D) printing process without affecting the materials' printability. In particular, a dye is a necessary ingredient in a formulation for a digital light processing 3D printing method to obtain precise and complex structures. Here, we use a photoluminescent dye specifically synthesized for this purpose that enables the production of 3D printed waveguides and splitters able to guide the luminescence. Moreover, copolymerizing the dye with the polymeric network during the printing process, we are able to maintain the solvatochromic properties of the dye toward different solvents in the printed structures, enabling the development of solvents' polarity sensors.

Additive Manufacturing of Transparent Silica Glass from Solutions

A sol, aqueous solution-based ink is presented for fabrication of 3D transparent silica glass objects with complex geometries, by a simple 3D printing process conducted at room temperature. The ink combines a hybrid ceramic precursor that can undergo both the photopolymerization reaction and a sol-gel process, both in the solution form, without any particles. The printing is conducted by localized photopolymerization with the use of a low-cost 3D printer. Following printing, upon aging and densifying, the resulting objects convert from a gel to a xerogel and then to a fused silica. The printed objects, which are composed of fused silica, are transparent and have tunable density and refractive indices.

The Investigation of the Waveguiding Properties of Silk Fibroin from the Visible to Near-Infrared Spectrum

Silk fibroin protein has been reinvented as a new optical material for biophotonic applications because of its optical transparency, biocompatibility, and easy fabrication process. It is used in various silk-based optical devices, which makes it desirable to investigate the optical properties of silk from diverse perspectives. This paper presents our investigation of the optical properties of silk fibroin, extracted from Bombyx mori cocoons. We have measured transmission spectra from the visible to near-infrared region and investigated waveguiding properties by the prism-coupling technique for five wavelengths (473.0, 632.8, 964.0, 1311, and 1552 nm). From the measurements, we determined the values of refractive indices. The measurements also proved waveguiding properties for all of the wavelengths. Optical scattering losses were measured by the fiber probe technique at 632.8 nm and were estimated to be 0.22 dB·cm⁻¹.

Biotinylated Photopolymers for 3D-Printed Unibody Lab-on-a-Chip Optical Platforms

The present work reports the first demonstration of straightforward fabrication of monolithic unibody lab-on-a-chip (ULOCs) integrating bioactive micrometric 3D scaffolds by means of multimaterial stereolithography (SL). To this end, a novel biotin-conjugated photopolymer is successfully synthesized and optimally formulated to achieve high-performance SL-printing resolution, as demonstrated by the SL-fabrication of biotinylated structures smaller than 100 µm. By optimizing a multimaterial single-run SL-based 3D-printing process, such biotinylated microstructures are incorporated within perfusion microchambers whose excellent optical transparency enables real-time optical microscopy analyses. Standard biotin-binding assays confirm the existence of biotin-heads on the surfaces of the embedded 3D microstructures and allow to demonstrate that the biofunctionality of biotin is not altered during the SL-printing, thus making it exploitable for further conjugation with other biomolecules. As a step forward, an in-line optical detection system is designed, prototyped via SL-printing and serially connected to the perfusion microchambers through customized world-to-chip connectors. Such detection system is successfully employed to optically analyze the solution flowing out of the microchambers, thus enabling indirect quantification of the concentration of target interacting biomolecules. The successful application of this novel biofunctional photopolymer as SL-material enables to greatly extend the versatility of SL to directly fabricate ULOCs with intrinsic biofunctionality.

3D-Printed Transparent Glass

Silica inks are developed, which may be 3D printed and thermally processed to produce optically transparent glass structures with sub-millimeter features in forms ranging from scaffolds to monoliths. The inks are composed of silica powder suspended in a liquid and are printed using direct ink writing. The printed structures are then dried and sintered at temperatures well below the silica melting point to form amorphous, solid, transparent glass structures. This technique enables the mold-free formation of transparent glass structures previously inaccessible using conventional glass fabrication processes.

Spontaneously Embedded Scattering Structures in a Flexible Substrate for Light Extraction

A flexible hazy substrate (FHS) with embedded air bubbles to increase light extraction efficiency of organic light-emitting diodes (OLEDs) is reported. In order to embed the air bubbles in the flexible substrate, micropatterned substrates are fabricated by plasma treatment, and then coated with a planarization layer. During the planarization layer coating, air bubbles are trapped between the substrate and the planarization layer. The haze of the FHS can be controlled from 1.7% to 68.4% by changing the size of micropatterns by adjusting the plasma treatment time. The FHS shows average haze of 68.4%, average total transmittance of 90.3%, and extremely flat surface with average roughness (R _a ) of 1.2 nm. Rigorous coupled-wave analysis and finite-difference time-domain simulations are conducted to demonstrate that the air bubbles in the substrate can effectively extract photons that are trapped in the substrate. The FHS increases the power efficiency of OLEDs by 22% and further increases by 91% combined with an external extraction layer. Moreover, the FHS has excellent mechanical flexibility. No defect has been observed after 10 000 bending cycles at bending radius of 4 mm.

Inkjet Printing of Soft, Stretchable Optical Waveguides through the Photopolymerization of High-Profile Linear Patterns

Optical waveguides have been fabricated via photopolymerization of stable, inkjet-printed patterns. In order to obtain high-profile lines, the properties of both the ink and the substrate were adjusted. We prove that suitable patterns, with contact angles close to 90°, can be printed by using not fully cured, "sticky" PDMS as a substrate. In addition, we propose a simple sliding-drop experiment to show the crucial difference in how the ink dewets the "sticky" and the fully cured substrate, which is otherwise difficult to demonstrate. The light attenuation vs strain curve of the obtained waveguides was determined experimentally and was found to be almost linear within the measured strain range.

Three-dimensional micro/nanoscale architectures: fabrication and applications

Three-dimensional (3D) functional solids with programmable hierarchical micro/nanoarchitectures are critical for several fundamental applications, including structural composites, microfluidics, photonics, and tissue engineering. Due to the broad range of application possibilities, a large amount of effort has been devoted to the in-depth exploration of various top-down and bottom-up strategies to construct these complex multi-dimensional structures. In this review, we introduce and discuss selected examples of fabrication techniques which have successfully developed large area, novel 3D functional architectures with exquisite control over their morphology at the nano/subnanolevel. Emphasis is placed on the nanofabrication techniques, their salient features as well as advantages. A summary of the emerging application possibilities of such structures, especially in biomedicine, energy, and device construction, is also discussed.

Microfluidic Printheads for Multimaterial 3D Printing of Viscoelastic Inks

Multimaterial 3D printing using microfluidic printheads specifically designed for seamless switching between two visco-elastic materials "on-the-fly" during fabrication is demonstrated. This approach opens new avenues for the digital assembly of functional matter with controlled compositional and property gradients at the microscale.

Capacitive soft strain sensors via multicore-shell fiber printing

A new method for fabricating textile integrable capacitive soft strain sensors is reported, based on multicore-shell fiber printing. The fiber sensors consist of four concentric, alternating layers of conductor and dielectric, respectively. These wearable sensors provide accurate and hysteresis-free strain measurements under both static and dynamic conditions.

25th anniversary article: Rational design and applications of hydrogels in regenerative medicine

Hydrogels are hydrophilic polymer-based materials with high water content and physical characteristics that resemble the native extracellular matrix. Because of their remarkable properties, hydrogel systems are used for a wide range of biomedical applications, such as three-dimensional (3D) matrices for tissue engineering, drug-delivery vehicles, composite biomaterials, and as injectable fillers in minimally invasive surgeries. In addition, the rational design of hydrogels with controlled physical and biological properties can be used to modulate cellular functionality and tissue morphogenesis. Here, the development of advanced hydrogels with tunable physiochemical properties is highlighted, with particular emphasis on elastomeric, light-sensitive, composite, and shape-memory hydrogels. Emerging technologies developed over the past decade to control hydrogel architecture are also discussed and a number of potential applications and challenges in the utilization of hydrogels in regenerative medicine are reviewed. It is anticipated that the continued development of sophisticated hydrogels will result in clinical applications that will improve patient care and quality of life.

25th anniversary article: ordered polymer structures for the engineering of photons and phonons

The engineering of optical and acoustic material functionalities via construction of ordered local and global architectures on various length scales commensurate with and well below the characteristic length scales of photons and phonons in the material is an indispensable and powerful means to develop novel materials. In the current mature status of photonics, polymers hold a pivotal role in various application areas such as light-emission, sensing, energy, and displays, with exclusive advantages despite their relatively low dielectric constants. Moreover, in the nascent field of phononics, polymers are expected to be a superior material platform due to the ability for readily fabricated complex polymer structures possessing a wide range of mechanical behaviors, complete phononic bandgaps, and resonant architectures. In this review, polymer-centric photonic and phononic crystals and metamaterials are highlighted, and basic concepts, fabrication techniques, selected functional polymers, applications, and emerging ideas are introduced.

A polymeric waveguide resonant mirror (RM) device for detection in microfluidic flow cells

A novel resonant mirror (RM) device, which consisted of silica sol-gel spacer and polystyrene waveguide layers on a standard microscope slide glass substrate, was developed in this work. The device was successfully used to measure the absorption spectrum of methylene blue with a limit of detection (LOD) of at most 20.8 μM at 635 nm and a minimum detectable absorption coefficient of 0.94 cm(-1). A RM device consisting of dye-doped polystyrene waveguide layer was then demonstrated to be suitable to monitor antibody-antigen (in this case, anti-IgG and IgG) binding and was shown to be capable of detecting at least 100 nM IgG. The sensitivity of the device was estimated to be 17.27° per refractive index unit (RIU), which corresponds to a resolution of 1.45 × 10(-4) RIU for the set-up used. The RM device developed in this work can be easily integrated with microfluidic devices to identify and quantify (bio) chemical species by either absorption spectroscopy or measurement of effective optical thickness or both. In addition, the device was fabricated using a simple and low cost fabrication technique, spin coating. Hence, it can be easily mass produced.

Micro-/nanostructured mechanical metamaterials

Mechanical properties of materials have long been one of the most fundamental and studied areas of materials science for a myriad of applications. Recently, mechanical metamaterials have been shown to possess extraordinary effective properties, such as negative dynamic modulus and/or density, phononic bandgaps, superior thermoelectric properties, and high specific energy absorption. To obtain such materials on appropriate length scales to enable novel mechanical devices, it is often necessary to effectively design and fabricate micro-/nano- structured materials. In this Review, various aspects of the micro-/nano-structured materials as mechanical metamaterials, potential tools for their multidimensional fabrication, and selected methods for their structural and performance characterization are described, as well as some prospects for the future developments in this exciting and emerging field.