Additive Manufacturing of 3D-Architected Multifunctional Metal Oxides

3D Nanoprinting of Heterogeneous Metal Oxides with High Shape Fidelity

3D nanoprinting can significantly enhance the performance of sensors, batteries, optoelectronic/microelectronic devices, etc. However, current 3D nanoprinting methods for metal oxides are suffering from three key issues including limited material applicability, serious shape distortion, and the difficulty of heterogeneous integration. This paper discovers a mechanism in which imidazole and acrylic acid synergistically coordinate with metal ions in water. Using the mechanism, this work develops a series of metal ion synergistic coordination water-soluble (MISCWS) resins for 3D nanoprinting of various metal oxides, including MnO2, Cr2O3, Co3O4, and ZnO, as well as heterogeneous structures of MnO2/NiO, Cr2O3/Al2O3, and ZnO/MgO. Besides, the synergistic coordination effect results in a 2.54-fold increase in inorganic mass fraction within the polymer, compared with previous works, which effectively mitigates the shape distortion of metal oxide microstructures. Based on this method, this work also demonstrates a 3D ZnO microsensor with a high sensitivity (1.113 million at 200 ppm NO2), surpassing the conventional 2D ZnO sensors by tenfold. The method yields high-fidelity 3D structures of heterogeneous metal oxides with nanoscale resolution, paving the way for applications such as sensing, micro-optics, energy storage, and microsystems.

Additive Manufacturing of Micro-Architected Copper based on an Ion-Exchangeable Hydrogel

Additive manufacturing (AM) of copper through laser-based processes poses challenges, primarily attributed to the high thermal conductivity and low laser absorptivity of copper powder or wire as the feedstock. Although the use of copper salts in vat photopolymerization-based AM techniques has garnered recent attention, achieving micro-architected copper with high conductivity and density has remained elusive. In this study, we present a facile and efficient process to create complex 3D micro-architected copper structures with superior electrical conductivity and hardness. The process entails the formulation of an ion-exchangeable photoresin, followed by the utilization of digital light processing (DLP) printing to sculpt 3D hydrogel scaffolds, which were transformed into Cu2+-chelated polymer frameworks (Cu-CPFs) with a high loading of Cu2+ ions through ion exchange, followed by debinding and sintering, results in the transformation of Cu-CPFs into miniaturized copper architectures. This methodology represents an efficient pathway for the creation of intricate micro-architected 3D metal structures.

Two-Photon Polymerization of Nanocomposites for Additive Manufacturing of Transparent Magnesium Aluminate Spinel Ceramics

Transparent polycrystalline magnesium aluminate (MAS) spinel ceramics are of great interest for industry and academia due to their excellent optical and mechanical properties. However, shaping of MAS is notoriously challenging especially on the microscale requiring hazardous etching methods. Therefore, a photochemically curable nanocomposite is demonstrated that can be structured using high-resolution two-photon lithography. The printed nanocomposites are converted intro transparent MAS by subsequent debinding, sintering, and hot isostatic pressing. The resulting transparent spinel ceramics exhibit a surface roughness Sq of only 10 nm and can be shaped with minimum feature sizes of down to 13 µm. This technology will be important for the production of microstructured ceramics used for optics, photonics, or photocatalysis.

4D printing for biomedical applications

While three-dimensional (3D) printing excels at fabricating static constructs, it fails to emulate the dynamic behavior of native tissues or the temporal programmability desired for medical devices. Four-dimensional (4D) printing is an advanced additive manufacturing technology capable of fabricating constructs that can undergo pre-programmed changes in shape, property, or functionality when exposed to specific stimuli. In this Perspective, we summarize the advances in materials chemistry, 3D printing strategies, and post-printing methodologies that collectively facilitate the realization of temporal dynamics within 4D-printed soft materials (hydrogels, shape-memory polymers, liquid crystalline elastomers), ceramics, and metals. We also discuss and present insights about the diverse biomedical applications of 4D printing, including tissue engineering and regenerative medicine, drug delivery, in vitro models, and medical devices. Finally, we discuss the current challenges and emphasize the importance of an application-driven design approach to enable the clinical translation and widespread adoption of 4D printing.

Microstructure-driven mechanical and electromechanical phenomena in additively manufactured nanocrystalline zinc oxide

Advances in nanoscale additive manufacturing (AM) offer great opportunities to expand nanotechnologies; however, the size effects in these printed remain largely unexplored. Using bothin situnanomechanical and electrical experiments and molecular dynamics (MD) simulations, this study investigates additively manufactured nano-architected nanocrystalline ZnO (nc-ZnO) with ∼7 nm grains and dimensions spanning 0.25-4μm. These nano-scale ceramics are fabricated through printing and subsequent burning of metal ion-containing hydrogels to produce oxide structures. Electromechanical behavior is shown to result from random ordering in the microstructure and can be modeled through a statistical treatment. A size effect in the failure behavior of AM nc-ZnO is also observed and characterized by the changes in deformation behavior and suppression of brittle failure. MD simulations provide insights to the role of grain boundaries and grain boundary plasticity on both electromechanical behavior and failure mechanisms in nc-ZnO. The frameworks developed in this paper extend to other AM nanocrystalline materials and provide quantification of microstructurally-drive limitations to precision in materials property design.

Low-temperature 3D printing of transparent silica glass microstructures

Transparent silica glass is one of the most essential materials used in society and industry, owing to its exceptional optical, thermal, and chemical properties. However, glass is extremely difficult to shape, especially into complex and miniaturized structures. Recent advances in three-dimensional (3D) printing have allowed for the creation of glass structures, but these methods involve time-consuming and high-temperature processes. Here, we report a photochemistry-based strategy for making glass structures of micrometer size under mild conditions. Our technique uses a photocurable polydimethylsiloxane resin that is 3D printed into complex structures and converted to silica glass via deep ultraviolet (DUV) irradiation in an ozone environment. The unique DUV-ozone conversion process for silica microstructures is low temperature (~220°C) and fast (<5 hours). The printed silica glass is highly transparent with smooth surface, comparable to commercial fused silica glass. This work enables the creation of arbitrary structures in silica glass through photochemistry and opens opportunities in unexplored territories for glass processing techniques.

3D-Architected Alkaline-Earth Perovskites

3D ceramic architectures are captivating geometrical features with an immense demand in optics. In this work, an additive manufacturing (AM) approach for printing alkaline-earth perovskite 3D microarchitectures is developed. The approach enables custom-made photoresists suited for two-photon lithography, permitting the production of alkaline-earth perovskite (BaZrO3 , CaZrO3 , and SrZrO3 ) 3D structures shaped in the form of octet-truss lattices, gyroids, or inspired architectures like sodalite zeolite, and C60 buckyballs with micrometric and nanometric feature sizes. Alkaline-earth perovskite morphological, structural, and chemical characteristics are studied. The optical properties of such perovskite architectures are investigated using cathodoluminescence and wide-field photoluminescence emission to estimate the lifetime rate and defects in BaZrO3 , CaZrO3 , and SrZrO3 . From a broad perspective, this AM methodology facilitates the production of 3D-structured mixed oxides. These findings are the first steps toward dimensionally refined high-refractive-index ceramics for micro-optics and other terrains like (photo/electro)catalysis.

3D printing of inorganic nanomaterials by photochemically bonding colloidal nanocrystals

3D printing of inorganic materials with nanoscale resolution offers a different materials processing pathway to explore devices with emergent functionalities. However, existing technologies typically involve photocurable resins that reduce material purity and degrade properties. We develop a general strategy for laser direct printing of inorganic nanomaterials, as exemplified by more than 10 semiconductors, metal oxides, metals, and their mixtures. Colloidal nanocrystals are used as building blocks and photochemically bonded through their native ligands. Without resins, this bonding process produces arbitrary three-dimensional (3D) structures with a large inorganic mass fraction (~90%) and high mechanical strength. The printed materials preserve the intrinsic properties of constituent nanocrystals and create structure-dictated functionalities, such as the broadband chiroptical responses with an anisotropic factor of ~0.24 for semiconducting cadmium chalcogenide nanohelical arrays.

A Generalized Polymer Precursor Ink Design for 3D Printing of Functional Metal Oxides

Three-dimensional-structured metal oxides have myriad applications for optoelectronic devices. Comparing to conventional lithography-based manufacturing methods which face significant challenges for 3D device architectures, additive manufacturing approaches such as direct ink writing offer convenient, on-demand manufacturing of 3D oxides with high resolutions down to sub-micrometer scales. However, the lack of a universal ink design strategy greatly limits the choices of printable oxides. Here, a universal, facile synthetic strategy is developed for direct ink writable polymer precursor inks based on metal-polymer coordination effect. Specifically, polyethyleneimine functionalized by ethylenediaminetetraacetic acid is employed as the polymer matrix for adsorbing targeted metal ions. Next, glucose is introduced as a crosslinker for endowing the polymer precursor inks with a thermosetting property required for 3D printing via the Maillard reaction. For demonstrations, binary (i.e., ZnO, CuO, In2O3, Ga2O3, TiO2, and Y2O3) and ternary metal oxides (i.e., BaTiO3 and SrTiO3) are printed into 3D architectures with sub-micrometer resolution by extruding the inks through ultrafine nozzles. Upon thermal crosslinking and pyrolysis, the 3D microarchitectures with woodpile geometries exhibit strong light-matter coupling in the mid-infrared region. The design strategy for printable inks opens a new pathway toward 3D-printed optoelectronic devices based on functional oxides.

Microfluidic Approaches for Microactuators: From Fabrication, Actuation, to Functionalization

Microactuators can autonomously convert external energy into specific mechanical motions. With the feature sizes varying from the micrometer to millimeter scale, microactuators offer many operation and control possibilities for miniaturized devices. In recent years, advanced microfluidic techniques have revolutionized the fabrication, actuation, and functionalization of microactuators. Microfluidics can not only facilitate fabrication with continuously changing materials but also deliver various signals to stimulate the microactuators as desired, and consequently improve microfluidic chips with multiple functions. Herein, this cross-field that systematically correlates microactuator properties and microfluidic functions is comprehensively reviewed. The fabrication strategies are classified into two types according to the flow state of the microfluids: stop-flow and continuous-flow prototyping. The working mechanism of microactuators in microfluidic chips is discussed in detail. Finally, the applications of microactuator-enriched functional chips, which include tunable imaging devices, micromanipulation tools, micromotors, and microsensors, are summarized. The existing challenges and future perspectives are also discussed. It is believed that with the rapid progress of this cutting-edge field, intelligent microsystems may realize high-throughput manipulation, characterization, and analysis of tiny objects and find broad applications in various fields, such as tissue engineering, micro/nanorobotics, and analytical devices.

White emission in 3D-printed phosphor microstructures

Microscale functional materials permit advanced applications in optics and photonics. This work presents the additive manufacturing of three-dimensional structured phosphors emitting red, green, blue, and white. The development is a step forward to realizing additive colour synthesis within complex architectures of relevance in integrated optics or light-emitting sources.

Macroscale Fabrication of Lightweight and Strong Porous Carbon Foams through Template-Coating Pair Design

Manufacturing of low-density-high-strength carbon foams can benefit the construction, transportation, and packaging industries. One successful route to lightweight and mechanically strong carbon foams involves pyrolysis of polymeric architectures, which is inevitably accompanied by drastic volumetric shrinkage (usually >98%). As such, a challenge of these materials lies in maintaining bulk dimensions of building struts that span orders of magnitude difference in length scale from centimeters to nanometers. This work demonstrates fabrication of macroscale low-density-high-strength carbon foams that feature exceptional dimensional stability through pyrolysis of robust template-coating pairs. The template serves as the architectural blueprint and contains strength-imparting properties (e.g., high node density and small strut dimensions); it is composed of a low char-yielding porous polystyrene backbone with a high carbonization-onset temperature. The coating serves to imprint and transcribe the template architecture into pyrolytic carbon; it is composed of a high char-yielding conjugated polymer with a relatively low carbonization-onset temperature. The designed carbonization mismatch enables structural inheritance, while the decomposition mismatch affords hollow struts, minimizing density. The carbons synthesized through this new framework exhibit remarkable dimensional stability (≈80% dimension retention; ≈50% volume retention) and some of the highest specific strengths (≈0.13 GPa g^-1 cm³ ) among reported carbon foams derived from porous polymer templates.

Controlled Desiccation of Preprinted Hydrogel Scaffolds Toward Complex 3D Microarchitectures

Additive manufacturing (AM) is the key to creating a wide variety of 3D structures with unique and programmable functionalities. Direct ink writing is one of the widely used AM technologies with numerous printable materials. However, the extrude-based method is limited by low fabrication resolution, which is confined to printing macrostructures. Herein, a new AM strategy is reported, using a low-cost extrusion 3D printer, to create 3D microarchitectures at the macroscopic level through controlled desiccation of preprinted hydrogel scaffolds followed by infilling objective components. A printable hydrogel with a high-water content ensures maximum shrinkage (≈99.5% in volume) of the printed scaffolds to achieve high resolution. Stable covalent cross-linking and a suitable drying rate enable uniform shrinkage of the scaffolds to retain their original architectures. Particularly, this method can be adapted to produce liquid-metal-based 3D circuits and nanocomposite-based microrobots, indicating its capability to fabricate functional and complex 3D architectures with micron-level resolution from different material systems.

Additive manufacturing of Zn with submicron resolution and its conversion into Zn/ZnO core-shell structures

Electrohydrodynamic redox 3D printing (EHD-RP) is an additive manufacturing (AM) technique with submicron resolution and multi-metal capabilities, offering the possibility to switch chemistry during deposition "on-the-fly". Despite the potential for synthesizing a large range of metals by electrochemical small-scale AM techniques, to date, only Cu and Ag have been reproducibly deposited by EHD-RP. Here, we extend the materials palette available to EHD-RP by using aqueous solvents instead of organic solvents, as used previously. We demonstrate deposition of Cu and Zn from sacrificial anodes immersed in acidic aqueous solvents. Mass spectrometry indicates that the choice of the solvent is important to the deposition of pure Zn. Additionally, we show that the deposited Zn structures, 250 nm in width, can be partially converted into semiconducting ZnO structures by oxidation at 325 °C in air.

Bioinspired Nanonetwork Hydroxyapatite from Block Copolymer Templated Synthesis for Mechanical Metamaterials

Inspired by Mantis shrimp, this work aims to suggest a bottom-up approach for the fabrication of nanonetwork hydroxyapatite (HAp) thin film using self-assembled polystyrene-block-polydimethylsiloxane (PS-b-PDMS) block copolymer (BCP) with a diamond nanostructure as a template for templated sol-gel reaction. By introducing poly(vinylpyrrolidone) (PVP) into precursors of calcium nitrate tetrahydrate and triethyl phosphite, which limits the growth of forming HAp nanoparticles, well-ordered nanonetwork HAp thin film can be fabricated. Based on nanoindentation results, the well-ordered nanonetwork HAp shows high energy dissipation compared to the intrinsic HAp. Moreover, the uniaxial microcompression test for the nanonetwork HAp shows high energy absorption per volume and high compression strength, outperforming many cellular materials due to the topologic effect of the well-ordered network at the nanoscale. This work highlights the potential of exploiting BCP templated synthesis to fabricate ionic solid materials with a well-ordered nanonetwork monolith, giving rise to the brittle-to-ductile transition, and thus appealing mechanical properties with the character of mechanical metamaterials.

Magnetically encoded 3D mesostructure with high-order shape morphing and high-frequency actuation

Inspired by origami/kirigami, three-dimensional (3D) mesostructures assembled via a mechanics-guided approach, with reversible and maneuverable shape-morphing capabilities, have attracted great interest with regard to a broad range of applications. Despite intensive studies, the development of morphable 3D mesostructures with high-order (multi-degree-of-freedom) deformation and untethered high-frequency actuation remains challenging. This work introduces a scheme for a magnetically encoded transferable 3D mesostructure, with polyethylene terephthalate (PET) film as the skeleton and discrete magnetic domains as actuation units, to address this challenge. The high-order deformation, including hierarchical, multidirectional and blending shape morphing, is realized by encoding 3D discrete magnetization profiles on the architecture through ultraviolet curing. Reconfigurable 3D mesostructures with a modest structural modulus (∼3 GPa) enable both high-frequency (∼55 Hz) and large-deformation (∼66.8%) actuation under an alternating magnetic field. Additionally, combined with the shape-retention and adhesion property of PET, these 3D mesostructures can be readily transferred and attached to many solid substrates. On this basis, diverse functional devices, including a switchable colour letter display, liquid mixer, sequential flashlight and biomimetic sliding robot, are demonstrated to offer new perspectives for robotics and microelectronics.

3D nanoprinting of semiconductor quantum dots by photoexcitation-induced chemical bonding

Three-dimensional (3D) laser nanoprinting allows maskless manufacturing of diverse nanostructures with nanoscale resolution. However, 3D manufacturing of inorganic nanostructures typically requires nanomaterial-polymer composites and is limited by a photopolymerization mechanism, resulting in a reduction of material purity and degradation of intrinsic properties. We developed a polymerization-independent, laser direct writing technique called photoexcitation-induced chemical bonding. Without any additives, the holes excited inside semiconductor quantum dots are transferred to the nanocrystal surface and improve their chemical reactivity, leading to interparticle chemical bonding. As a proof of concept, we printed arbitrary 3D quantum dot architectures at a resolution beyond the diffraction limit. Our strategy will enable the manufacturing of free-form quantum dot optoelectronic devices such as light-emitting devices or photodetectors.

Nanocellulose Paper Semiconductor with a 3D Network Structure and Its Nano-Micro-Macro Trans-Scale Design

Semiconducting nanomaterials with 3D network structures exhibit various fascinating properties such as electrical conduction, high permeability, and large surface areas, which are beneficial for adsorption, separation, and sensing applications. However, research on these materials is substantially restricted by the limited trans-scalability of their structural design and tunability of electrical conductivity. To overcome this challenge, a pyrolyzed cellulose nanofiber paper (CNP) semiconductor with a 3D network structure is proposed. Its nano-micro-macro trans-scale structural design is achieved by a combination of iodine-mediated morphology-retaining pyrolysis with spatially controlled drying of a cellulose nanofiber dispersion and paper-crafting techniques, such as microembossing, origami, and kirigami. The electrical conduction of this semiconductor is widely and systematically tuned, via the temperature-controlled progressive pyrolysis of CNP, from insulating (10¹² Ω cm) to quasimetallic (10^-2 Ω cm), which considerably exceeds that attained in other previously reported nanomaterials with 3D networks. The pyrolyzed CNP semiconductor provides not only the tailorable functionality for applications ranging from water-vapor-selective sensors to enzymatic biofuel cell electrodes but also the designability of macroscopic device configurations for stretchable and wearable applications. This study provides a pathway to realize structurally and functionally designable semiconducting nanomaterials and all-nanocellulose semiconducting technology for diverse electronics.

Colloidal oxide nanoparticle inks for micrometer-resolution additive manufacturing of three-dimensional gas sensors

Micrometer-resolution 3D printing of functional oxides is of growing importance for the fabrication of micro-electromechanical systems (MEMSs) with customized 3D geometries. Compared to conventional microfabrication methods, additive manufacturing presents new opportunities for the low-cost, energy-saving, high-precision, and rapid manufacturing of electronics with complex 3D architectures. Despite these promises, methods for printable oxide inks are often hampered by challenges in achieving the printing resolution required by today's MEMS electronics and integration capabilities with various other electronic components. Here, a novel, facile ink design strategy is presented to overcome these challenges. Specifically, we first prepare a high-solid loading (∼78 wt%) colloidal suspension that contains polyethyleneimine (PEI)-coated stannic dioxide (SnO₂) nanoparticles, followed by PEI desorption that is induced by nitric acid (HNO₃) titration to optimize the rheological properties of the printable inks. Our achieved ∼3-5 μm printing resolution is at least an order of magnitude higher than those of other printed oxide studies employing nanoparticle ink-based printing methods demonstrated previously. Finally, various SnO₂ structures were directly printed on a MEMS-based microelectrode for acetylene detection application. The gas sensitivity measurements reveal that the device performance is strongly dependent on the printed SnO₂ structures. Specifically, the 3D structured SnO₂ gas sensor exhibits the highest response of ∼ 29.9 to 100 ppm acetylene with the fastest total response time of ∼ 65.8 s. This work presents a general ink formulation and printing strategy for functional oxides, which further provides a pathway for the additive manufacturing of oxide-based MEMSs.

3D Laser Nanoprinting of Optically Functionalized Structures with Effective-Refractive-Index Tailorable TiO2 Nanoparticle-Doped Photoresin

The advanced direct laser printing of functional devices with tunable effective index is a key research topic in numerous emerging fields, especially in micro-/nano-optics, nanophotonics, and electronics. Photosensitized nanocomposites, consisting of high-index materials (e.g., titanium dioxide, TiO₂) embedded in polymer matrix, are emerging as attractive platforms for advanced additive manufacturing. Unfortunately, in the currently applied techniques, the preparation of optically functionalized structures based on these photosensitized nanocomposites is still hampered by many issues like hydrolysis reaction, high-temperature calcinations, and, especially, the complexity of experimental procedures. In this study, we demonstrate a feasible strategy for fabricating micro-/nanostructures with a flexibly manipulated effective refractive index by incorporating TiO₂ nanoparticles in the matrix of acrylate resin, i.e., TiO₂-based photosensitized nanocomposites. It was found that the effective refractive index of nanocomposite can be easily tuned by altering the concentration of titanium dioxide nanoparticles in the monomer matrix. For TiO₂ nanoparticle concentrations up to 30 wt%, the refractive index can be increased over 11.3% (i.e., altering from 1.50 of pure monomer to 1.67 at 532 nm). Based on such a photosensitized nanocomposite, the grating structures defined by femtosecond laser nanoprinting can offer vivid colors, ranging from crimson to magenta, as observed in the dark-field images. The minimum printing width and printing resolution are estimated at around 70 nm and 225 nm, indicating that the proposed strategy may pave the way for the production of versatile, scalable, and functionalized opto-devices with controllable refractive indices.

3D Printing and Pyrolysis of Optical ZrO2 Nanostructures by Two-Photon Lithography: Reduced Shrinkage and Crystallization Mediated by Nanoparticles Seeds

Two-photon lithography is a potential route to produce high-resolution 3D ceramics. However, the large shrinkage due to the elimination of an important organic counterpart of the printed material during debinding/sintering remains a lock to further development of this technology. To limit this phenomenon, an original approach based on a composite resin incorporating 45 wt% ultrasmall (5 nm) zirconia stabilized nanoparticles into the zirconium acrylate precursor is proposed to process 3D zirconia microlattices and nanostructured optical surfaces. Interestingly, the nanoparticles are used both as seeds allowing control of the crystallographic phase formed during the calcination process and as structural stabilizing agent preventing important shrinkage of the printed ceramic. After 3D photolithography and pyrolysis, the weight and volume loss of the microstructures are drastically reduced as compared to similar systems processed with the reference resin without nanoparticles, and stable 3D microstructures of cubic zirconia are obtained with high spatial resolution. In the case of a patterned surface, the refractive index of 2.1 leads to a diffraction efficiency large enough to obtain microfocusing with linewidths of 0.1 µm, and the demonstration of a microlens array with a period as small as 0.8 µm.

High Resolution Patterning of an Organic-Inorganic Photoresin for the Fabrication of Platinum Microstructures

Platinum (Pt) is an interesting material for many applications due to its high chemical resilience, outstanding catalytic activity, high electrical conductivity, and high melting point. However, microstructuring and especially 3D microstructuring of platinum is a complex process, based on expensive and specialized equipment often suffering from very slow processing speeds. In this work, organic-inorganic photoresins, which can be structured using direct optical lithography as well as two-photon lithography (TPL) with submicrometer resolution and high-throughput is presented. The printed structures are subsequently converted to high-purity platinum using thermal debinding of the binder and reduction of the salt. With this technique, complex 3D structures with a 3D resolution of 300 nm were fabricated. At a layer thickness of 35 nm, the patterns reach a high conductivity of 67% compared to bulk platinum. Microheaters, thermocouple sensors as well as a Lab-on-a-Chip system are presented as exemplary applications. This technology will enable a broad range of application from electronics, sensing and heating elements to 3D photonics and metamaterials.

Electrocatalysis for the Oxygen Evolution Reaction in Acidic Media: Progress and Challenges

The oxygen evolution reaction (OER) is the efficiency-determining half-reaction process of high-demand, electricity-driven water splitting due to its sluggish four-electron transfer reaction. Tremendous effects on developing OER catalysts with high activity and strong acid-tolerance at high oxidation potentials have been made for proton-conducting polymer electrolyte membrane water electrolysis (PEMWE), which is one of the most promising future hydrogen-fuel-generating technologies. This review presents recent progress in understanding OER mechanisms in PEMWE, including the adsorbate evolution mechanism (AEM) and the lattice-oxygen-mediated mechanism (LOM). We further summarize the latest strategies to improve catalytic performance, such as surface/interface modification, catalytic site coordination construction, and electronic structure regulation of catalytic centers. Finally, challenges and prospective solutions for improving OER performance are proposed.

Optimal and continuous multilattice embedding

Because of increased geometric freedom at a widening range of length scales and access to a growing material space, additive manufacturing has spurred renewed interest in topology optimization of parts with spatially varying material properties and structural hierarchy. Simultaneously, a surge of micro/nanoarchitected materials have been demonstrated. Nevertheless, multiscale design and micro/nanoscale additive manufacturing have yet to be sufficiently integrated to achieve free-form, multiscale, biomimetic structures. We unify design and manufacturing of spatially varying, hierarchical structures through a multimicrostructure topology optimization formulation with continuous multimicrostructure embedding. The approach leads to an optimized layout of multiple microstructural materials within an optimized macrostructure geometry, manufactured with continuously graded interfaces. To make the process modular and controllable and to avoid prohibitively expensive surface representations, we embed the microstructures directly into the 3D printer slices. The ideas provide a critical, interdisciplinary link at the convergence of material and structure in optimal design and manufacturing.

Two-Photon Polymerization of Nanocomposites for the Fabrication of Transparent Fused Silica Glass Microstructures

Fused silica glass is the material of choice for many high-performance components in optics due to its high optical transparency combined with its high thermal, chemical, and mechanical stability. Especially, the generation of fused silica microstructures is of high interest for microoptical and biomedical applications. Direct laser writing (DLW) is a suitable technique for generating such devices, as it enables nearly arbitrary structuring down to the sub-micrometer level. In this work, true 3D structuring of transparent fused silica glass using DLW with tens of micrometer resolution and a surface roughness of R_a  ≈ 6 nm is demonstrated. The process uses a two-photon curable silica nanocomposite resin that can be structured by DLW, with the printout being convertible to transparent fused silica glass via thermal debinding and sintering. This technology will enable a plethora of applications from next-generation optics and photonics to microfluidic and biomedical applications with resolutions on the scale of tens of micrometers.

Hydrogel-based Additive Manufacturing of Lithium Cobalt Oxide

Three-dimensional (3D) multicomponent metal oxides with complex architectures could enable previously impossible energy storage devices, particularly lithium-ion battery (LIB) electrodes with fully controllable form factors. Existing additive manufacturing approaches for fabricating 3D multicomponent metal oxides rely on particle-based or organic-inorganic binders, which are limited in their resolution and chemical composition, respectively. In this work, aqueous metal salt solutions are used as metal precursors to circumvent these limitations, and provide a platform for 3D printing multicomponent metal oxides. As a proof-of-concept, architected lithium cobalt oxide (LCO) structures are fabricated by first synthesizing a homogenous lithium and cobalt nitrate aqueous photoresin, and then using it with digital light processing printing to obtain lithium and cobalt ion containing hydrogels. The 3D hydrogels are calcined to obtain micro-porous self-similar LCO architectures with a resolution of ~100μm. These free-standing, binder- and conductive additive-free LCO structures are integrated as cathodes into LIBs, and exhibit electrochemical capacity retention of 76% over 100 cycles at C/10. This facile approach to fabricating 3D LCO structures can be extended to other materials by tailoring the identity and stoichiometry of the metal salt solutions used, providing a versatile method for the fabrication of multicomponent metal oxides with complex 3D architectures.

Direct Optical Lithography of Colloidal Metal Oxide Nanomaterials for Diffractive Optical Elements with 2π Phase Control

Spatially patterned dielectric materials are ubiquitous in electronic, photonic, and optoelectronic devices. These patterns are typically made by subtractive or additive approaches utilizing vapor-phase reagents. On the other hand, recent advances in solution-phase synthesis of oxide nanomaterials have unlocked a materials library with greater compositional, microstructural, and interfacial tunability. However, methods to pattern and integrate these nanomaterials in real-world devices are less established. In this work, we directly optically pattern oxide nanoparticles (NPs) by mixing them with photosensitive diazo-2-naphthol-4-sulfonic acid and irradiating with widely available 405 nm light. We demonstrate the direct optical lithography of ZrO₂, TiO₂, HfO₂, and ITO NPs and investigate the chemical and physical changes responsible for this photoinduced decrease in solubility. Micron-thick layers of amorphous ZrO₂ NPs were patterned with micron resolution and shown to allow 2π phase control of visible light. We also show multilayer patterning and use it to fabricate features with different thicknesses and distinct structural colors. Upon annealing at 400 °C, the deposited ZrO₂ structures have excellent optical transparency across a wide wavelength range (0.3-10 μm), a high refractive index (n = 1.84 at 633 nm), and are optically smooth. We then fabricate diffractive optical elements, such as binary phase diffraction gratings, that show efficient diffractive behavior and good thermal stability. Different oxide NPs can also be mixed prior to patterning, providing a high level of material tunability. This work demonstrates a general patterning approach that harnesses the processability and diversity of colloidal oxide nanomaterials for use in photonic applications.

Microplotter-Printed On-Chip Combinatorial Library of Ink-Derived Multiple Metal Oxides as an "Electronic Olfaction" Unit

Information about the surrounding atmosphere at a real timescale significantly relies on available gas sensors to be efficiently combined into multisensor arrays as electronic olfaction units. However, the array's performance is challenged by the ability to provide orthogonal responses from the employed sensors at a reasonable cost. This issue becomes more demanded when the arrays are designed under an on-chip paradigm to meet a number of emerging calls either in the internet-of-things industry or in situ noninvasive diagnostics of human breath, to name a few, for small-sized low-powered detectors. The recent advances in additive manufacturing provide a solid top-down background to develop such chip-based gas-analytical systems under low-cost technology protocols. Here, we employ hydrolytically active heteroligand complexes of metals as ink components for microplotter patterning a multioxide combinatorial library of chemiresistive type at a single chip equipped with multiple electrodes. To primarily test the performance of such a multisensor array, various semiconducting oxides of the p- and n-conductance origins based on pristine and mixed nanocrystalline MnO_x, TiO₂, ZrO₂, CeO₂, ZnO, Cr₂O₃, Co₃O₄, and SnO₂ thin films, of up to 70 nm thick, have been printed over hundred μm areas and their micronanostructure and fabrication conditions are thoroughly assessed. The developed multioxide library is shown to deliver at a range of operating temperatures, up to 400 °C, highly sensitive and highly selective vector signals to different, but chemically akin, alcohol vapors (methanol, ethanol, isopropanol, and n-butanol) as examples at low ppm concentrations when mixed with air. The suggested approach provides us a promising way to achieve cost-effective and well-performed electronic olfaction devices matured from the diverse chemiresistive responses of the printed nanocrystalline oxides.

3D Printing of Micrometer-Sized Transparent Ceramics with On-Demand Optical-Gain Properties

Transparent ceramics are usually polycrystalline materials, which are wildly used in many optical applications, such as lasers. As of today, the fabrication of transparent ceramic structures is still limited to conventional fabrication methods, which do not enable the formation of complex structures. A new approach for 3D printing of micrometer-size, transparent ceramic structures is presented. By using a solution of metal salts that can undergo a sol-gel process and photopolymerization by two-photon printing, micrometer-sized yttrium aluminum garnet (YAG) structures doped with neodymium (Nd) are fabricated. The resulting structures are not only transparent in the visible spectrum but can also emit light at 1064 nm due to the doping with Nd. By using solution-based precursors, without any particles, the sintering can be performed under air at ambient pressure and at a relatively low temperature, compared to conventional processes for YAG. The crystalline structure is imaged at atomic resolution by ultrahigh-resolution scanning transmission electron microscopy (STEM), indicating that the doped Nd atoms are located at the yttrium positions. Such miniaturized structures can be used for diverse applications, e.g., optical components in high-intensity laser systems, which require heat resistance, or as light sources in optical circuits.

Additive Manufacturing of High-Refractive-Index, Nanoarchitected Titanium Dioxide for 3D Dielectric Photonic Crystals

Additive manufacturing at small scales enables advances in micro- and nanoelectromechanical systems, micro-optics, and medical devices. Materials that lend themselves to AM at the nanoscale, especially for optical applications, are limited. State-of-the-art AM processes for high-refractive-index materials typically suffer from high porosity and poor repeatability and require complex experimental procedures. We developed an AM process to fabricate complex 3D architectures out of fully dense titanium dioxide (TiO₂) with a refractive index of 2.3 and nanosized critical dimensions. Transmission electron microscopy (TEM) analysis proves this material to be rutile phase of nanocrystalline TiO₂, with an average grain size of 110 nm and <1% porosity. Proof-of-concept woodpile architectures with 300-600 nm beam dimensions exhibit a full photonic band gap centered at 1.8-2.9 μm, as revealed by Fourier-transform infrared spectroscopy (FTIR) and supported by plane wave expansion simulations. The developed AM process enables advances in 3D MEMS, micro-optics, and prototyping of 3D dielectric PhCs.