3D-Printed Anisotropic Polymer Materials for Functional Applications

Simultaneous Color- and Dose-Controlled Thiol-Ene Resins for Multimodulus 3D Printing with Programmable Interfacial Gradients

Drawing inspiration from nature's own intricate designs, synthetic multimaterial structures have the potential to offer properties and functionality that exceed those of the individual components. However, several contemporary hurdles, from a lack of efficient chemistries to processing constraints, preclude the rapid and precise manufacturing of such materials. Herein, the development of a photocurable resin comprising color-selective initiators is reported, triggering disparate polymerization mechanisms between acrylate and thiol functionality. Exposure of the resin to UV light (365 nm) leads to the formation of a rigid, highly crosslinked network via a radical chain-growth mechanism, while violet light (405 nm) forms a soft, lightly crosslinked network via an anionic step-growth mechanism. The efficient photocurable resin is employed in multicolor digital light processing 3D printing to provide structures with moduli spanning over two orders of magnitude. Furthermore, local intensity (i.e., grayscale) control enables the formation of programmable stiffness gradients with ≈150× change in modulus occurring across sharp (≈200 µm) and shallow (≈9 mm) interfaces, mimetic of the human knee entheses and squid beaks, respectively. This study provides composition-processing-property relationships to inform advanced manufacturing of next-generation multimaterial objects having a myriad of applications from healthcare to education.

Consistent Thermal Conductivities of Spring-Like Structured Polydimethylsiloxane Composites under Large Deformation

Flexible and highly thermally conductive materials with consistent thermal conductivity (λ) during large deformation are urgently required to address the heat accumulation in flexible electronics. In this study, spring-like thermal conduction pathways of silver nanowire (S-AgNW) fabricated by 3D printing are compounded with polydimethylsiloxane (PDMS) to prepare S-AgNW/PDMS composites with excellent and consistent λ during deformation. The S-AgNW/PDMS composites exhibit a λ of 7.63 W m-1 K-1 at an AgNW amount of 20 vol%, which is ≈42 times that of PDMS (0.18 W m-1 K-1) and higher than that of AgNW/PDMS composites with the same amount and random dispersion of AgNW (R-AgNW/PDMS) (5.37 W m-1 K-1). Variations in the λ of 20 vol% S-AgNW/PDMS composites are less than 2% under a deformation of 200% elongation, 50% compression, or 180° bending, which benefits from the large deformation characteristics of S-AgNW. The heat-transfer coefficient (0.29 W cm-2 K-1) of 20 vol% S-AgNW/PDMS composites is ≈1.3 times that of the 20 vol% R-AgNW/PDMS composites, which reduces the temperature of a full-stressed central processing unit by 6.8 °C compared to that using the 20 vol% R-AgNW/PDMS composites as a thermally conductive material in the central processing unit.

Effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing: An in vitro study

PURPOSE

This in vitro study investigated the effect of build orientation on the wear resistance and hardness of denture teeth fabricated using digital light processing (DLP) compared to other denture tooth materials.

METHODS

Disc-shaped specimens were prepared using denture tooth monomers and DLP devices in three build orientations: 0°, 45°, and 90°. Specimens of the same shape were fabricated using denture tooth materials for subtractive manufacturing, commercially available polymethylmethacrylate (PMMA) resin, and composite resin. The wear resistance was evaluated as the wear volume loss after 50,000 wear cycles using a ball-on-disc wear device in water for two-body wear and poppy seed slurry for three-body wear. The Vickers hardness values of the materials were measured. Two-way and one-way analyses of variance were performed for wear resistance and hardness, respectively, followed by Tukey's honest significance test.

RESULTS

The interaction between the denture tooth resins and maximum wear volume was significant (P < 0.01). The 0° build orientation exhibited the lowest wear volume in the three-body wear test and the highest hardness among the three build orientations. The 0° DLP-fabricated specimens demonstrated significantly less wear volume than that of the PMMA specimens and a wear volume comparable to that of the milled specimens. However, the 0° DLP-fabricated specimens showed significantly lower hardness than that of the milled and PMMA specimens. The composite resin specimens exhibited the highest wear resistance and hardness.

CONCLUSIONS

A 0° build orientation is recommended for DLP-fabricated denture teeth compared to 45° and 90° orientations to achieve greater wear resistance and hardness.

Omnidirectional anisotropic embedded 3D bioprinting

Anisotropic microstructures resulting from a well-ordered arrangement of filamentous extracellular matrix (ECM) components or cells can be found throughout the human body, including skeletal muscle, corneal stroma, and meniscus, which play a crucial role in carrying out specialized physiological functions. At present, due to the isotropic characteristics of conventional hydrogels, the construction of freeform cell-laden anisotropic structures with high-bioactive hydrogels is still a great challenge. Here, we proposed a method for direct embedded 3D cell-printing of freeform anisotropic structure with shear-oriented bioink (GelMA/PEO). This study focuses on the establishment of an anisotropic embedded 3D bioprinting system, which effectively utilizes the shear stress generated during the extrusion process to create cells encapsulating tissues with distinct anisotropy. In conjunction with the water-solubility of PEO and the in-situ encapsulation effect provided by the carrageenan support bath, high-precise cell-laden bioprinting of intricate anisotropic and porous bionic artificial tissues can be effectively implemented in one-step. Additionally, anisotropic permeable blood vessel has been taken as a representation to validate the effectiveness of the shear-oriented bioink system in fabricating intricate structures with distinct directional characteristics. Lastly, the successful preparation of muscle patches with anisotropic properties and their guiding role for cell cytoskeleton extension have provided a significant research foundation for the application of the anisotropic embedded 3D bioprinting system in the ex-vivo production and in-vivo application of anisotropic artificial tissues.

Recent Advances in 4D Printing of Advanced Materials and Structures for Functional Applications

4D printing has attracted tremendous worldwide attention during the past decade. This technology enables the shape, property, or functionality of printed structures to change with time in response to diverse external stimuli, making the original static structures alive. The revolutionary 4D-printing technology offers remarkable benefits in controlling geometric and functional reconfiguration, thereby showcasing immense potential across diverse fields, including biomedical engineering, electronics, robotics, and photonics. Here, a comprehensive review of the latest achievements in 4D printing using various types of materials and different additive manufacturing techniques is presented. The state-of-the-art strategies implemented in harnessing various 4D-printed structures are highlighted, which involve materials design, stimuli, functionalities, and applications. The machine learning approach explored for 4D printing is also discussed. Finally, the perspectives on the current challenges and future trends toward further development in 4D printing are summarized.

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.

Regioselective super-assembly of Prussian blue analogue

The construction of high-asymmetrical structures demonstrates significant potential in improving the functionality and distinctness of nanomaterials, but remains a considerable challenge. Herein, we develop a one-pot method to fabricate regioselective super-assembly of Prussian blue analogue (PBA) -- a PBA anisotropic structure (PBA-AS) decorated with epitaxial modules--using a step-by-step epitaxial growth on a rapidly self-assembled cubic substrate guided by thiocyanuric acid (TCA) molecules. The epitaxial growth units manifest as diverse geometric shapes, which are predominantly concentrated on the {100}, {111}, or {100}+{111} crystal plane of the cubic substrate. The crystal plane and morphology of epitaxial module can be regulated by changing the TCA concentration and reaction temperature, enabling a high level of controllability over specific assembly sites and structures. To illustrate the advantage of the asymmetrical structure, phosphated PBA-AS demonstrates improved performance in the oxygen evolution reaction compared to simple phosphated PBA nanocube. This method offers valuable insights for designing asymmetrical nanomaterials with intricate architectures and versatile functionalities.

Volume-Metallization 3D-Printed Polymer Composites

3D printing polymer or metal can achieve complicated structures while lacking multifunctional performance. Combined printing of polymer and metal is desirable and challenging due to their insurmountable mismatch in melting-point temperatures. Here, a novel volume-metallization 3D-printed polymer composite (VMPC) with bicontinuous phases for enabling coupled structure and function, which are prepared by infilling low-melting-point metal (LM) to controllable porous configuration is reported. Based on vacuum-assisted low-pressure conditions, LM is guided by atmospheric pressure action and overcomes surface tension to spread along the printed polymer pore channel, enabling the complete filling saturation of porous structures for enhanced tensile strength (up to 35.41 MPa), thermal (up to 25.29 Wm-1K-1) and electrical (>106 S m-1) conductivities. The designed 3D-printed microstructure-oriented can achieve synergistic anisotropy in mechanics (1.67), thermal (27.2), and electrical (>1012) conductivities. VMPC multifunction is demonstrated, including customized 3D electronics with elevated strength, electromagnetic wave-guided transport and signal amplification, heat dissipation device for chip temperature control, and storage components for thermoelectric generator energy conversion with light-heat-electricity.

Chemical Circularity in 3D Printing with Biobased Δ-Valerolactone

Digital Light Processing (DLP) is a vat photopolymerization-based 3D printing technology that fabricates parts typically made of chemically crosslinked polymers. The rapidly growing DLP market has an increasing demand for polymer raw materials, along with growing environmental concerns. Therefore, circular DLP printing with a closed-loop recyclable ink is of great importance for sustainability. The low-ceiling temperature alkyl-substituted δ-valerolactone (VL) is an industrially accessible biorenewable feedstock for developing recyclable polymers. In this work, acrylate-functionalized poly(δ-valerolactone) (PVLA), synthesized through the ring-opening transesterification polymerization of VL, is used as a platform photoprecursor to improve the chemical circularity in DLP printing. A small portion of photocurable reactive diluent (RD) turns the unprintable PVLA into DLP printable ink. Various photocurable monomers can serve as RDs to modulate the properties of printed structures for applications like sacrificial molds, soft actuators, sensors, etc. The intrinsic depolymerizability of PVLA is well preserved, regardless of whether the printed polymer is a thermoplastic or thermoset. The recovery yield of virgin quality VL monomer is 93% through direct bulk thermolysis of the printed structures. This work proposes the utilization of depolymerizable photoprecursors and highlights the feasibility of biorenewable VL as a versatile material platform toward circular DLP printing.

An organic/inorganic hybrid soft material for supramolecular adhesion

Thioctic acid (TA) has been widely used to construct soft materials via supramolecular copolymerization with organic chemicals. In this study, TA and the inorganic compound MoS2 are used to fabricate poly[TA-MoS2] via dynamic covalent and supramolecular interactions. Poly[TA-MoS2] exhibits good and long-lasting adhesion performance on various artificial surfaces, with an adhesion strength up to 3.72 MPa (15 days). Further, it exhibits tough adhesion effects in an aqueous environment. Moreover, poly[TA-MoS2] displays good thermal processing behavior, thus enabling its molding through 3D printing.

Hierarchical Composite with Self-Adaptive Anisotropic Deformation for Thermal Protection System

Rigid thermal protection materials such as ultra-high-temperature ceramics are desirable for applications in aerospace vehicles, but few materials can currently satisfy the emerging high-temperature sealing requirements for dynamic gaps created by the mismatch of the thermal expansion of different protection layers. Here, we design and fabricate a flexible biomimetic anisotropic deformation composite by multilayer cocuring onto fiber fabrics. It displays superior anisotropic deformation, whose longitudinal expansion ratio is 48 times greater than the transverse expansion ratio at specific temperatures. Furthermore, the ordered carbon structure created by transition-metal-catalyzed graphitization and the C/Si synergistic effect resulting from the combination of biomimetic fiber fabrics and SR enable the in situ formation of a high-temperature-resistant SiC crystalline phase within the char layer, ultimately resulting in exceptional thermal protection properties. By constructing hollow structures in situ, the back temperature of the composite, which is only 4.33 mm thick, is stabilized at 140 °C under the condition of continuous butane flame ablation (1300 °C) for 420 s. Multilayer structure and flexible features can facilitate large-scale preparation and arbitrary cutting and bending, adapted to different thermal protection areas.

Lignin: A multi-faceted role/function in 3D printing inks

3D printing technology demonstrates significant potential for the rapid fabrication of tailored geometric structures. Nevertheless, the prevalent use of fossil-derived compositions in printable inks within the realm of 3D printing results in considerable environmental pollution and ecological consequences. Lignin, the second most abundant biomass source on earth, possesses attributes such as cost-effectiveness, renewability, biodegradability, and non-toxicity. Enriched with active functional groups including hydroxyl, carbonyl, carboxyl, and methyl, coupled with its rigid aromatic ring structure and inherent anti-oxidative and thermoplastic properties, lignin emerges as a promising candidate for formulating printable inks. This comprehensive review presents the utilization of lignin, either in conjunction with functional materials or through the modification of lignin derivatives, as the primary constituent (≥50 wt%) for formulating printable inks across photo-curing-based (SLA/DLP) and extrusion-based (DIW/FDM) printing technologies. Furthermore, lignin as an additive with multi-faceted roles/functions in 3D printing inks is explored. The effects of lignin on the properties of printing inks and printed objects are evaluated. Finally, this review outlines future perspectives, emphasizing key obstacles and potential opportunities for facilitating the high-value utilization of lignin in the realm of 3D printing.

Additive Manufacturing of Stretchable Multi-Walled Carbon Nanotubes/Thermoplastic Polyurethanes Conducting Polymers for Strain Sensing

With the development of science and technology, flexible sensors play an indispensable role in body monitoring. Rapid prototyping of high-performance flexible sensors has become an important method to develop flexible sensors. The purpose of this study was to develop a flexible resin with multi-walled carbon nanotubes (MWCNTs) for the rapid fabrication of flexible sensors using digital light processing additive manufacturing. In this study, MWCNTs were mixed in thermoplastic polyurethane (TPU) photosensitive resin to prepare polymer-matrix composites, and a flexible strain sensor was prepared using self-developed additive equipment. The results showed that the 1.2 wt% MWCNTs/TPU composite flexible sensor had high gauge factor of 9.988 with a linearity up to 45% strain and high mechanical durability (1000 cycles). Furthermore, the sensor could be used for gesture recognition and monitoring and has good performance. This method is expected to provide a new idea for the rapid personalized forming of flexible sensors.

Design and Optimization of 3D-Printed Variable Cross-Section I-Beams Reinforced with Continuous and Short Fibers

By integrating fiber-reinforced composites (FRCs) with Three-dimensional (3D) printing, the flexibility of lightweight structures was promoted while eliminating the mold's limitations. The design of the I-beam configuration was performed according to the equal-strength philosophy. Then, a multi-objective optimization analysis was conducted based on the NSGA-II algorithm. 3D printing was utilized to fabricate I-beams in three kinds of configurations and seven distinct materials. The flexural properties of the primitive (P-type), the designed (D-type), and the optimized (O-type) configurations were verified via three-point bending testing at a speed of 2 mm/min. Further, by combining different reinforcements, including continuous carbon fibers (CCFs), short carbon fibers (SCFs), and short glass fibers (SGFs) and distinct matrices, including polyamides (PAs), and polylactides (PLAs), the 3D-printed I-beams were studied experimentally. The results indicate that designed and optimized I-beams exhibit a 14.46% and 30.05% increase in the stiffness-to-mass ratio and a 7.83% and 40.59% increment in the load-to-mass ratio, respectively. The CCFs and SCFs result in an outstanding accretion in the flexural properties of 3D-printed I-beams, while the accretion is 2926% and 1070% in the stiffness-to-mass ratio and 656.7% and 344.4% in the load-to-mass ratio, respectively. For the matrix, PAs are a superior choice compared to PLAs for enhancing the positive impact of reinforcements.

Fabrication of Oriented Polycrystalline MOF Superstructures

The field of metal-organic frameworks (MOFs) has progressed beyond the design and exploration of powdery and single-crystalline materials. A current challenge is the fabrication of organized superstructures that can harness the directional properties of the individual constituent MOF crystals. To date, the progress in the fabrication methods of polycrystalline MOF superstructures has led to close-packed structures with defined crystalline orientation. By controlling the crystalline orientation, the MOF pore channels of the constituent crystals can be aligned along specific directions: these systems possess anisotropic properties including enhanced diffusion along specific directions, preferential orientation of guest species, and protection of functional guests. In this perspective, we discuss the current status of MOF research in the fabrication of oriented polycrystalline superstructures focusing on the specific crystalline directions of orientation. Three methods are examined in detail: the assembly from colloidal MOF solutions, the use of external fields for the alignment of MOF particles, and the heteroepitaxial ceramic-to-MOF growth. This perspective aims at promoting the progress of this field of research and inspiring the development of new protocols for the preparation of MOF systems with oriented pore channels, to enable advanced MOF-based devices with anisotropic properties.

3D Printing of Flow-Inspired Anisotropic Patterns with Liquid Crystalline Polymers

Anisotropic materials formed by living organisms possess remarkable mechanical properties due to their intricate microstructure and directional freedom. In contrast, human-made materials face challenges in achieving similar levels of directionality due to material and manufacturability constraints. To overcome these limitations, an approach using 3D printing of self-assembling thermotropic liquid crystal polymers (LCPs) is presented. Their high stiffness and strength is granted by nematic domains aligning during the extrusion process. Here, a remarkably wide range of Young's modulus from 3 to 40 GPa is obtained by utilizing directionality of the nematic flow the printing process.   By determining a relationship between stiffness, nozzle diameter, and line width, a design space where shaping and mechanical performance can be combined is identified. The ability to print LCPs with on-the-fly width changes to accommodate arbitrary spatially varying directions is demonstrated. This unlocks the possibility to manufacture exquisite patterns inspired by fluid dynamics with steep curvature variations. Utilizing the synergy between this path-planning method and LCPs, functional objects with stiffness and curvature gradients can be 3D-printed, offering potential applications in lightweight sustainable structures embedding crack-mitigation strategies. This method also opens avenues for studying and replicating intricate patterns observed in nature, such as wood or turbulent flow using 3D printing.

Oriented Self-assembly of Flexible MOFs Nanocrystals into Anisotropic Superstructures with Homogeneous Hydrogels Behaviors

Building of metal-organic frameworks (MOFs) homogeneous hydrogels made by spontaneous crystallization remains a significant challenge. Inspired by anisotropically structured materials in nature, an oriented super-assembly strategy to construct micro-scale MOFs superstructure is reported, in which the strong intermolecular interactions between zirconium-oxygen (Zr─O) cluster and glutamic acid are utilized to drive the self-assembly of flexible nanoribbons into pumpkin-like microspheres. The confined effect between water-flexible building blocks and crosslinked hydrogen networks of superstructures achieved a mismatch transformation of MOFs powders into homogeneous hydrogels. Importantly, the elastic and rigid properties of hydrogels can be simply controlled by precise modulation of coordination and self-assembly for anisotropic superstructure. Experimental results and theoretical calculations demonstrates that MOFs anisotropic superstructure exhibits dynamic double networks with a superior water harvesting capacity (119.73 g g-1 ) accompanied with heavy metal removal (1331.67 mg g-1 ) and strong mechanical strength (Young's modulus of 0.3 GPa). The study highlights the unique possibility of tailoring MOFs superstructure with homogeneous hydrogel behavior for application in diverse fields.

A 3D-Printed Ferromagnetic Liquid Crystal Elastomer with Programmed Dual-Anisotropy and Multi-Responsiveness

Liquid crystal elastomers (LCE) and magnetic soft materials are promising active materials in many emerging fields, such as soft robotics. Despite the high demand for developing active materials that combine the advantages of LCE and magnetic actuation, the lack of independent programming of the LCE nematic order and magnetization in a single material still hinders the desired multi-responsiveness. In this study, a ferromagnetic LCE (magLCE) ink with nematic order and magnetization is developed that can be independently programmed to be anisotropic, referred to as "dual anisotropy", via a customized 3D-printing platform. The magLCE ink is fabricated by dispersing ferromagnetic microparticles in the LCE matrix, and a 3D-printing platform is created by integrating a magnet with 3-DoF motion into an extrusion-based 3D printer. In addition to magnetic fields, magLCEs can also be actuated by heating sources (either environmental heating or photo-heating of the embedded ferromagnetic microparticles) with a high energy density and tunable actuation temperature. A programmed magLCE strip robot is demonstrated with enhanced adaptability to complex environments (different terrains, magnetic fields, and temperatures) using a multi-actuation strategy. The magLCE also has potential applications in mechanical memory, as demonstrated by the multistable mechanical metastructure array with remote writability and stable memory.

Robotization of Three-Point Bending Mechanical Tests Using PLA/TPU Blends as an Example in the 0-100% Range

This article presents the development of an automated three-point bending testing system using a robot to increase the efficiency and precision of measurements for PLA/TPU polymer blends as implementation high-throughput measurement methods. The system operates continuously and characterizes the flexural properties of PLA/TPU blends with varying TPU concentrations. This study aimed to determine the effect of TPU concentration on the strength and flexural stiffness, surface properties (WCA), thermal properties (TGA, DSC), and microscopic characterization of the studied blends.

Preparation and Analysis of Structured Color Janus Droplets Based on Microfluidic 3D Droplet Printing

The microfluidic technique for the three-dimensional (3D) printing of Janus droplets offers precise control over their size, orientation, and positioning. The proposed approach investigates the impact of variables such as the volume ratio of the oil phase, droplet size, and the ratio of nonionic surfactants on the dimensions of the structured color apertures of Janus droplets. The findings reveal that structured color apertures modulate accurately. Furthermore, fabricating color patterns facilitates cat, fish, and various other specific shapes using structured color Janus droplets. The color patterns exhibit temperature-sensitive properties, enabling them to transition between display and concealed states. Herein, the adopted microfluidic technique creates Janus droplets with customizable characteristics and uniform size, solving orientation as well as space arrangement problems. This approach holds promising applications for optical devices, sensors, and biomimetic systems.

Three/Four-Dimensional Printed PLA Nano/Microstructures: Crystallization Principles and Practical Applications

Compared to traditional methods, three/four-dimensional (3D/4D) printing technologies allow rapid prototyping and mass customization, which are ideal for preparing nano/microstructures of soft polymer materials. Poly (lactic acid) (PLA) is a biopolymer material widely used in additive manufacturing (AM) because of its biocompatibility and biodegradability. Unfortunately, owing to its intrinsically poor nucleation ability, a PLA product is usually in an amorphous state after industrial processing, leading to some undesirable properties such as a barrier property and low thermal resistance. Crystallization mediation offers a most practical way to improve the properties of PLA products. Herein, we summarize and discuss 3D/4D printing technologies in the processing of PLA nano/microstructures, focusing on crystallization principles and practical applications including bio-inspired structures, flexible electronics and biomedical engineering mainly reported in the last five years. Moreover, the challenges and prospects of 3D/4D printing technologies in the fabrication of high-performance PLA materials nano/microstructures will also be discussed.

In Situ Filler Addition for Homogeneous Dispersion of Carbon Nanotubes in Multi Jet Fusion-Printed Elastomer Composites

The dispersibility of fillers determines their effect on the mechanical properties and anisotropy of the 3D-printed polymeric composites. Nanoscale fillers have the tendency to aggregate, resulting in the deterioration of part performance. An in situ filler addition method using the newly developed dual-functional toughness agents (TAs) is proposed in this work for the homogeneous dispersion of carbon nanotubes (CNTs) in elastomer composites printed via multi jet fusion. The CNTs added in the TAs serve as an infrared absorbing colorant for selective powder fusion, as well as the strengthening and toughening fillers. The printability of the TA is theoretically deduced based on the measured physical properties, which are subsequently verified experimentally. The printing parameters and agent formulation are optimized to maximize the mechanical performance of the printed parts. The printed elastomer parts show significant improvement in strength and toughness for all printing orientations and alleviation of the mechanical anisotropy originating from the layer-wise fabrication manner. This in situ filler addition method using tailorable TAs is applicable for fabricating parts with site-specific mechanical properties and is promising in assisting the scalable manufacturing of 3D-printed elastomers.

Scalable microfluidic fabrication of vertically aligned two-dimensional nanosheets for superior thermal management

Two-dimensional (2D) nanosheets have been assembled into various macroscopic structures for wide engineering applications. To fully explore their exceptional thermal, mechanical, and electrical properties, 2D nanosheets must be aligned into highly ordered structures due to their strong structural anisotropy. Structures stacked layer by layer such as films and fibers have been readily assembled from 2D nanosheets due to their planar geometry. However, scalable manufacturing of macroscopic structures with vertically aligned 2D nanosheets remains challenging, given their large lateral size with a thickness of only a few nanometers. Herein, we report a scalable and efficient microfluidics-enabled sheet-aligning process to assemble 2D nanosheets into a large-area film with a highly ordered vertical alignment. By applying microchannels with a high aspect ratio, 2D nanosheets were well aligned vertically under strong channel size confinement and high flow shear stress. A vertically aligned graphene sheet film was obtained and applied to effectively improve the heat transfer of thermal interfacial materials (TIMs). Superior through-plane thermal conductivity of 82.7 W m-1 K-1 at a low graphene content of 11.8 vol% was measured for vertically aligned TIMs. Thus, they demonstrate exceptional thermal management performance for switching power supplies with high reliability.

Recent Advances in 4D Printing of Liquid Crystal Elastomers

Liquid crystal elastomers (LCEs) are renowned for their large, reversible, and anisotropic shape change in response to various external stimuli due to their lightly cross-linked polymer networks with an oriented mesogen direction, thus showing great potential for applications in robotics, bio-medics, electronics, optics, and energy. To fully take advantage of the anisotropic stimuli-responsive behaviors of LCEs, it is preferable to achieve a locally controlled mesogen alignment into monodomain orientations. In recent years, the application of 4D printing to LCEs opens new doors for simultaneously programming the mesogen alignment and the 3D geometry, offering more opportunities and higher feasibility for the fabrication of 4D-printed LCE objects with desirable stimuli-responsive properties. Here, the state-of-the-art advances in 4D printing of LCEs are reviewed, with emphasis on both the mechanisms and potential applications. First, the fundamental properties of LCEs and the working principles of the representative 4D printing techniques are briefly introduced. Then, the fabrication of LCEs by 4D printing techniques and the advantages over conventional manufacturing methods are demonstrated. Finally, perspectives on the current challenges and potential development trends toward the 4D printing of LCEs are discussed, which may shed light on future research directions in this new field.

Stimuli-Triggered Multishape, Multimode, and Multistep Deformations Designed by Microfluidic 3D Droplet Printing

Elastomers generally possess low Young's modulus and high failure strain, which are widely used in soft robots and intelligent actuators. However, elastomers generally lack diverse functionalities, such as stimulated shape morphing, and a general strategy to implement these functionalities into elastomers is still challenging. Here, a microfluidic 3D droplet printing platform is developed to design composite elastomers architected with arrays of functional droplets. Functional droplets with controlled size, composition, position, and pattern are designed and implemented in the composite elastomers, imparting functional performances to the systems. The composited elastomers are sensitive to stimuli, such as solvent, temperature, and light, and are able to demonstrate multishape (bow- and S-shaped), multimode (gradual and sudden), and multistep (one- and two-step) deformations. Based on the unique properties of droplet-embedded composite elastomers, a variety of stimuli-responsive systems are developed, including designable numbers, biomimetic flowers, and soft robots, and a series of functional performances are achieved, presenting a facile platform to impart diverse functionalities into composite elastomers by microfluidic 3D droplet printing.

Lignin-Based Materials for Additive Manufacturing: Chemistry, Processing, Structures, Properties, and Applications

The utilization of lignin, the most abundant aromatic biomass component, is at the forefront of sustainable engineering, energy, and environment research, where its abundance and low-cost features enable widespread application. Constructing lignin into material parts with controlled and desired macro- and microstructures and properties via additive manufacturing has been recognized as a promising technology and paves the way to the practical application of lignin. Considering the rapid development and significant progress recently achieved in this field, a comprehensive and critical review and outlook on three-dimensional (3D) printing of lignin is highly desirable. This article fulfils this demand with an overview on the structure of lignin and presents the state-of-the-art of 3D printing of pristine lignin and lignin-based composites, and highlights the key challenges. It is attempted to deliver better fundamental understanding of the impacts of morphology, microstructure, physical, chemical, and biological modifications, and composition/hybrids on the rheological behavior of lignin/polymer blends, as well as, on the mechanical, physical, and chemical performance of the 3D printed lignin-based materials. The main points toward future developments involve hybrid manufacturing, in situ polymerization, and surface tension or energy driven molecular segregation are also elaborated and discussed to promote the high-value utilization of lignin.

A robust and 3D-printed solar evaporator based on naturally occurring molecules

The interfacial solar desalination has been considered a promising method to address the worldwide water crisis without sophisticated infrastructures and additional energy consumption. Although various advanced solar evaporators have been developed, their practical applications are still restricted by the unsustainable materials and the difficulty of precise customization for structure to escort high solar-thermal efficiency. To address these issues, we employed two kinds of naturally occurring molecules, tannic acid and iron (III), to construct a low-cost, highly efficient and durable interfacial solar evaporator by three-dimensional (3D) printing. Based on a rational structural design, a robust and 3D-printed evaporator with conical array surface structure was developed, which could promote the light harvesting capacity significantly via the multiple reflections and anti-reflection effects on the surface. By optimizing the height of the conical arrays, the 3D-printed evaporator with tall-cone structure could achieve a high evaporation rate of 1.96 kg m^-2 h^-1 under one sun illumination, with a photothermal conversion efficiency of 94.4%. Moreover, this evaporator was also proved to possess excellent desalination performance, recycle stability, anti-salt property, underwater oil resistance, as well as adsorption capacity of organic dye contaminants for multipurpose water purification applications. It was believed that this study could provide a new strategy to fabricate low-cost, structural regulated solar evaporators for alleviating the dilemma of global water scarcity using abundant naturally occurring building blocks.

Shape Morphing by Topological Patterns and Profiles in Laser-Cut Liquid Crystal Elastomer Kirigami

Programming shape changes in soft materials requires precise control of the directionality and magnitude of their mechanical response. Among ordered soft materials, liquid crystal elastomers (LCEs) exhibit remarkable and programmable shape shifting when their molecular order changes. In this work, we synthesized, remotely programmed, and modeled reversible and complex morphing in monolithic LCE kirigami encoded with predesigned topological patterns in its microstructure. We obtained a rich variety of out-of-plane shape transformations, including auxetic structures and undulating morphologies, by combining different topological microstructures and kirigami geometries. The spatiotemporal shape-shifting behaviors are well recapitulated by elastodynamics simulations, revealing that the complex shape changes arise from integrating the custom-cut geometry with local director profiles defined by topological defects inscribed in the material. Different functionalities, such as a bioinspired fluttering butterfly, a flower bud, dual-rotation light mills, and dual-mode locomotion, are further realized. Our proposed LCE kirigami with topological patterns opens opportunities for the future development of multifunctional devices for soft robotics, flexible electronics, and biomedicine.

Recent Advances on High-Performance Polyaryletherketone Materials for Additive Manufacturing

Polyaryletherketone (PAEK) is emerging as an important high-performance polymer material in additive manufacturing (AM) benefiting from its excellent mechanical properties, good biocompatibility, and high-temperature stability. The distinct advantages of AM facilitate the rapid development of PAEK products with complex customized structures and functionalities, thereby enhancing their applications in various fields. Herein, the recent advances on AM of high-performance PAEKs are comprehensively reviewed, concerning the materials properties, AM processes, mechanical properties, and potential applications of additively manufactured PAEKs. To begin, an introduction to fundamentals of AM and PAEKs, as well as the advantages of AM of PAEKs is provided. Discussions are then presented on the material properties, AM processes, processing-matter coupling mechanism, thermal conductivity, crystallization characteristics, and microstructures of AM-processed PAEKs. Thereafter, the mechanical properties and anisotropy of additively manufactured PAEKs are discussed in depth. Their representative applications in biomedical, aerospace, electronics, and other fields are systematically presented. Finally, current challenges and possible solutions are discussed for the future development of high-performance AM polymers.

Poly(thioctic acid): From Bottom-Up Self-Assembly to 3D-Fused Deposition Modeling Printing

Inspired by the bottom-up assembly in nature, an artificial self-assembly pattern is introduced into 3D-fused deposition modeling (FDM) printing to achieve additive manufacturing on the macroscopic scale. Thermally activated polymerization of thioctic acid (TA) enabled the bulk construction of poly(TA), and yielded unique time-dependent self-assembly. Freshly prepared poly(TA) can spontaneously and continuously transfer into higher-molecular-weight species and low-molecular-weight TA monomers. Poly(TA) and the newly formed TA further assembled into self-reinforcing materials via microscopic-phase separation. Bottom-up self-assembly patterns on different scales are fully realized by 3D FDM printing of poly(TA): thermally induced polymerization of TA (microscopic-scale assembly) to poly(TA) and 3D printing (macroscopic-scale assembly) of poly(TA) are simultaneously achieved in the 3D-printing process; after 3D printing, the poly(TA) modes show mechanically enhanced features over time, arising from the microscopic self-assembly of poly(TA) and TA. This study clearly demonstrates that micro- and macroscopic bottom-up self-assembly can be applied in 3D additive manufacturing.

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

Fused Deposition Modelling (FDM) is an actively growing additive manufacturing (AM) technology due to its ability to produce complex shapes in a short time. AM, also known as 3-dimensional printing (3DP), creates the desired shape by adding material, preferably by layering contoured layers on top of each other. The need for low cost, design flexibility and automated manufacturing processes in industry has triggered the development of FDM. However, the mechanical properties of FDM printed parts are still weaker compared to conventionally manufactured products. Numerous studies and research have already been carried out to improve the mechanical properties of FDM printed parts. Reinforce polymer matrix with fiber is one of the possible solutions. Furthermore, reinforcement can enhance the thermal and electrical properties of FDM printed parts. Various types of fibers and manufacturing methods can be adopted to reinforce the polymer matrix for different desired outcomes. This review emphasizes the fiber types and fiber insertion techniques of FDM 3D printed fiber reinforcement polymer composites. A brief overview of fused deposition modelling, polymer sintering and voids formation during FDM printing is provided, followed by the basis of fiber reinforced polymer composites, type of fibers (synthetic fibers vs. natural fibers, continuous vs. discontinuous fiber) and the composites' performance. In addition, three different manufacturing methods of fiber reinforced thermoplastics based on the timing and location of embedding the fibers, namely 'embedding before the printing process (M1)', 'embedding in the nozzle (M2)', and 'embedding on the component (M3)', are also briefly reviewed. The performance of the composites produced by three different methods were then discussed.

Multi-Jet Fusion 3D Voxel Printing of Conductive Elastomers

3D voxel printing enables the fabrication of parts with site-specific materials and properties at voxel-scale resolution, while the current research mainly focuses on the variations in mechanical properties and colors. In this work, the design and fabrication of voxelated conductive elastomers using Multi Jet Fusion 3D voxel printing actualized by a newly developed multifunctional agent (MA) are investigated. The MA, mainly consisting of carbon nanotubes and poly(3,4-ethylenedioxythiophene) polystyrene sulfonate, serves as an infrared-absorbing colorant, a reinforcement, and a conductive filler simultaneously. By controlling the drop-on-demand dispensing of the agents on thermoplastic polyurethane powder, the electrical conductivity across a single printed part can be tailored over a wide range from 10^-10 to 10^-1 S cm^-1 at a voxel resolution of ≈100 µm. Assembly-free strain sensors comprising conductive sensing layers and insulating frames are fabricated to demonstrate the capability of the technique in manufacturing all-printed wearable devices.

Printing nanoparticle-based isotropic/anisotropic networks for directional electrical circuits

With the demand for integrated nanodevices, anisotropic conductive films are one type of interconnection structure for electronic components, which have been widely used for improving the integration of the system in printed circuit boards. This work presents a template-assisted printing strategy for the fabrication of nanoparticle-based networks with multi electrical properties. By manipulating the microfluid behavior under the guidance of the grid-shaped template, the continuity of liquid bridges can be precisely controlled in two directions. The isotropous circuits with crossbar paths, discrete paths as well as unidirectional paths are obtained, which achieve the switching of on/off states in the circuits. This work demonstrates a new type of directional circuits by the template-assisted printing method, which provides an effective fabrication strategy for electrical components and integrated systems.

Three Dimensional Printing of Bioinspired Crossed-Lamellar Metamaterials with Superior Toughness for Syntactic Foam Substitution

Biological materials such as conch shells with crossed-lamellar textures hold impressive mechanical properties due to their capability to realize effective crack control and energy dissipation through the structural synergy of interfacial modulus mismatch and lamellar orientation disparity. Integrating this mechanism with mechanical metamaterial design can not only avoid the catastrophic post-yield stress drop found in traditional architectural materials with uniform lattice structures but also effectively maintain the stress level and improve the energy absorption ability. Herein, a novel bioinspired design strategy that combines regional particularity and overall cyclicity is proposed to innovate the connotation of long-range periodicity inside the metamaterial, in which the node constraint gradient and crossed-lamellar struts corresponding to the core features of conch shells are able to guide the deformation sequence with a self-strengthening response during compression. Detailed in situ experiments and finite element analysis confirm that the rotated broad layer stacking can shorten and impede the shear bands, further transforming the deformation of bioinspired metamaterial into a progressive, hierarchical way, highlighted by the cross-layer hysteresis. Even based on a brittle polymeric resin, excellent specific energy absorption capacity [4544 kJ/kg] has been achieved in this architecture, which far exceeds the reported metal-based syntactic foams for two orders of magnitude. These results offer new opportunities for the bioinspired metamaterials to substitute the widespread syntactic foams in specific applications required for both lightweight and energy absorption.

Advances in 4D printing of liquid crystalline elastomers: materials, techniques, and applications

Liquid crystalline elastomers (LCEs) are polymer networks exhibiting anisotropic liquid crystallinity while maintaining elastomeric properties. Owing to diverse polymeric forms and self-alignment molecular behaviors, LCEs have fascinated state-of-the-art efforts in various disciplines other than the traditional low-molar-mass display market. By patterning order to structures, LCEs demonstrate reversible high-speed and large-scale actuations in response to external stimuli, allowing for close integration with 4D printing and architectures of digital devices, which is scarcely observed in homogeneous soft polymer networks. In this review, we collect recent advances in 4D printing of LCEs, with emphases on synthesis and processing methods that enable microscopic changes in the molecular orientation and hence macroscopic changes in the properties of end-use objects. Promising potentials of printed complexes include fields of soft robotics, optics, and biomedical devices. Within this scope, we elucidate the relationships among external stimuli, tailorable morphologies in mesophases of liquid crystals, and programmable topological configurations of printed parts. Lastly, perspectives and potential challenges facing 4D printing of LCEs are discussed.

Current Advances and Future Perspectives of Advanced Polymer Processing for Bone and Tissue Engineering: Morphological Control and Applications

Advanced polymer processing has received extensive attention due to its unique control of complex force fields and customizability, and has been widely applied in various fields, especially in preparation of functional devices for bioengineering and biotechnology. This review aims to provide an overview of various advanced polymer processing techniques including rotation extrusion, electrospinning, micro injection molding, 3D printing and their recent progresses in the field of cell proliferation, bone repair, and artificial blood vessels. This review dose not only attempts to provide a comprehensive understanding of advanced polymer processing, but also aims to guide for design and fabrication of next-generation device for biomedical engineering.

Inkjet-Printed Flexible Strain-Gauge Sensor on Polymer Substrate: Topographical Analysis of Sensitivity

Inkjet-printed strain gauges on flexible substrates have recently been investigated for biomedical motion detection as well as the monitoring of structural deformation. This study performed a topographical analysis of an inkjet-printed strain gauge constructed using silver conductive ink on a PET (polyethylene terephthalate) substrate. Serpentine strain-gauge sensors of various thicknesses and widths were fabricated using inkjet printing and oven sintering. The fabricated gauge sensors were attached to curved surfaces, and gauge factors ranging from 2.047 to 3.098 were recorded. We found that the cross-sectional area of the printed strain gauge was proportional to the gauge factor. The correlation was mathematically modelled as y = 0.4167ln(x) + 1.3837, for which the coefficient of determination (R2) was 0.8383.