Metallization of 3D Printed Polymers and Their Application as a Fully Functional Water-Splitting System

3D printed energy devices: generation, conversion, and storage

The energy devices for generation, conversion, and storage of electricity are widely used across diverse aspects of human life and various industry. Three-dimensional (3D) printing has emerged as a promising technology for the fabrication of energy devices due to its unique capability of manufacturing complex shapes across different length scales. 3D-printed energy devices can have intricate 3D structures for significant performance enhancement, which are otherwise impossible to achieve through conventional manufacturing methods. Furthermore, recent progress has witnessed that 3D-printed energy devices with micro-lattice structures surpass their bulk counterparts in terms of mechanical properties as well as electrical performances. While existing literature focuses mostly on specific aspects of individual printed energy devices, a brief overview collectively covering the wide landscape of energy applications is lacking. This review provides a concise summary of recent advancements of 3D-printed energy devices. We classify these devices into three functional categories; generation, conversion, and storage of energy, offering insight on the recent progress within each category. Furthermore, current challenges and future prospects associated with 3D-printed energy devices are discussed, emphasizing their potential to advance sustainable energy solutions.

Programmable and Modularized Gas Sensor Integrated by 3D Printing

The rapid advancement of intelligent manufacturing technology has enabled electronic equipment to achieve synergistic design and programmable optimization through computer-aided engineering. Three-dimensional (3D) printing, with the unique characteristics of near-net-shape forming and mold-free fabrication, serves as an effective medium for the materialization of digital designs into usable devices. This methodology is particularly applicable to gas sensors, where performance can be collaboratively optimized by the tailored design of each internal module including composition, microstructure, and architecture. Meanwhile, diverse 3D printing technologies can realize modularized fabrication according to the application requirements. The integration of artificial intelligence software systems further facilitates the output of precise and dependable signals. Simultaneously, the self-learning capabilities of the system also promote programmable optimization for the hardware, fostering continuous improvement of gas sensors for dynamic environments. This review investigates the latest studies on 3D-printed gas sensor devices and relevant components, elucidating the technical features and advantages of different 3D printing processes. A general testing framework for the performance evaluation of customized gas sensors is proposed. Additionally, it highlights the superiority and challenges of programmable and modularized gas sensors, providing a comprehensive reference for material adjustments, structure design, and process modifications for advanced gas sensor devices.

Current perspectives, challenges, and future directions in the electrochemical detection of microplastics

Microplastics (5 μm) are a developing threat that contaminate every environmental compartment. The detection of these contaminants is undoubtedly an important topic of study because of their high potential to cause harm to ecosystems. For many years, scientists have been assiduously striving to surmount the obstacle of detection restrictions and minimize the likelihood of receiving results that are either false positives or false negatives. This study covers the current state of electrochemical sensing technology as well as its application as a low-cost analytical platform for the detection and characterization of novel contaminants. Examples of detection mechanisms, electrode modification procedures, device configuration, and performance are given to show how successful these approaches are for monitoring microplastics in the environment. Additionally included are the recent developments in nanoimpact techniques. Compared to electrochemical methods for microplastic remediation, the use of electrochemical sensors for microplastic detection has received very little attention. With an overview of microplastic electrochemical sensors, this review emphasizes the promise of existing electrochemical remediation platforms toward sensor design and development. In order to enhance the monitoring of these substances, a critical assessment of the requirements for future research, challenges associated with detection, and opportunities is provided. In addition to-or instead of-the now-in-use laboratory-based analytical equipment, these technologies can be utilized to support extensive research and manage issues pertaining to microplastics in the environment and other matrices.

Angle-independent solar radiation capture by 3D printed lattice structures for efficient photoelectrochemical water splitting

Photoelectrochemical water splitting is one of the sustainable routes to renewable hydrogen production. One of the challenges to deploying photoelectrochemical (PEC) based electrolyzers is the difficulty in the effective capture of solar radiation as the illumination angle changes throughout the day. Herein, we demonstrate a method for the angle-independent capture of solar irradiation by using transparent 3 dimensional (3D) lattice structures as the photoanode in PEC water splitting. The transparent 3D lattice structures were fabricated by 3D printing a silica sol-gel followed by aging and sintering. These transparent 3D lattice structures were coated with a conductive indium tin oxide (ITO) thin film and a Mo-doped BiVO₄ photoanode thin film by dip coating. The sheet resistance of the conductive lattice structures can reach as low as 340 Ohms per sq for ∼82% optical transmission. The 3D lattice structures furnished large volumetric current densities of 1.39 mA cm^-3 which is about 2.4 times higher than a flat glass substrate (0.58 mA cm^-3) at 1.23 V and 1.5 G illumination. Further, the 3D lattice structures showed no significant loss in performance due to a change in the angle of illumination, whereas the performance of the flat glass substrate was significantly affected. This work opens a new paradigm for more effective capture of solar radiation that will increase the solar to energy conversion efficiency.

Less Is More: Hollow-Truss Microlattice Metamaterials with Dual Sound Dissipation Mechanisms and Enhanced Broadband Sound Absorption

Being a lightweight material with high design freedoms, there are increasing research interests in microlattice metamaterials as sound absorbers. However, thus far, microlattices are limited to one sound dissipation mechanism, and this inhibits their broadband absorption capabilities. Herein, as opposed to improving performances via the addition of features, a dissipation mechanism is subtractively introduced by hollowing out the struts of the microlattice. Then, a class of hollow-truss metamaterial (HTM) that is capable of harnessing dual concurrent dissipation mechanisms from its complex truss interconnectivity and its hollow interior is presented. Experimental sound absorption measurements reveal superior and/or customizable absorption properties in the HTMs as compared to their constitutive solid-trusses. An optimal HTM displays a high average broadband coefficient of 0.72 at a low thickness of 24 mm. Numerically derived, a dissipation theorem based on the superimposed acoustic impedance of the critically coupled resistance and reactance of the outer-solid and inner-hollow phases, across different frequency bands, is proposed in the HTM. Complementary mechanical property studies also reveal improved compressive toughness in the HTMs. This work demonstrates the potential of hollow-trusses, where they gain the dissipation mechanism through the subtraction of the material and display excellent acoustic properties.

Tunable hydrogen enhancement of Ce3+ doped CdS with different Poisson's ratio support

In this article, a 3D photocatalytic support with different Poisson's ratio was used for the first time to control the photocatalytic production rate of hydrogen. It was created by a stereo-lithography method, and the support with the most negative Poisson's ratio got the best result. The Poisson's ratio of the 3D structure influences the rate of hydrogen production, and it is important for the photocatalyst supports to be porous for light to penetrate into them. A series of Ce doped CdS photocatalysts were produced and immobilized on 3D multicellular Al₂O₃ supports. By changing the proportion of Ce³⁺ doped into the CdS photocatalysts 1 % of Ce³⁺ exhibited optimal hydrogen production, which was 222.9 % compared to that of the pure CdS. Using the 3D photocatalytic support with different Poisson's ratio, the photocatalytic production rate of hydrogen increased by 128 %.

Recent advances and perspectives of 3D printed micro-supercapacitors: from design to smart integrated devices

3D-printed micro-supercapacitors (MSCs) have emerged as the ideal candidates for energy storage devices owing to their unique characteristics of miniaturization, structural diversity, and integration. Exploring the 3D printing technology for various materials and architectures of MSCs is key to realizing customization and optimizing the performance of 3D-printed MSCs. In this review, we summarize the latest progress in 3D-printed MSCs with regards to general printing approaches, printable materials, and rational design considerations. Specifically, several general types of 3D printing techniques (their working principles, available materials, resolutions, advantages, and disadvantages) and their applications to fabricate electrodes with different energy storage mechanisms, and various electrolytes, are summarized. We further discuss research directions in terms of integrated systems with other electronics. Finally, future perspectives on the research and development directions in this important field are further discussed.

Nanostructured Plasma Polymerized Fluorocarbon Films for Drop Coating Deposition Raman Spectroscopy (DCDRS) of Liposomes

Raman spectroscopy is one of the most used biodetection techniques. However, its usability is hampered in the case of low concentrated substances because of the weak intensity of the Raman signal. To overcome this limitation, the use of drop coating deposition Raman spectroscopy (DCDRS), in which the liquid samples are allowed to dry into well-defined patterns where the non-volatile solutes are highly concentrated, is appropriate. This significantly improves the Raman sensitivity when compared to the conventional Raman signal from solution/suspension. As DCDRS performance strongly depends on the wetting properties of substrates, we demonstrate here that the smooth hydrophobic plasma polymerized fluorocarbon films prepared by magnetron sputtering (contact angle 108°) are well-suited for the DCDRS detection of liposomes. Furthermore, it was proved that even better improvement of the Raman signal might be achieved if the plasma polymer surfaces are roughened. In this case, 100% higher intensities of Raman signal are observed in comparison with smooth fluorocarbon films. As it is shown, this effect, which has no influence on the profile of Raman spectra, is connected with the increased hydrophobicity of nanostructured fluorocarbon films. This results in the formation of dried liposomal deposits with smaller diameters and higher preconcentration of liposomes.

Additively Manufactured Deformation-Recoverable and Broadband Sound-Absorbing Microlattice Inspired by the Concept of Traditional Perforated Panels

Noise pollution is a highly detrimental daily health hazard. Sound absorbers, such as the traditionally used perforated panels, find widespread applications. Nonetheless, modern product designs call for material novelties with enhanced performance and multifunctionality. The advent of additive manufacturing has brought about the possibilities of functional materials design to be based on structures rather than chemistry. With this in mind, herein, the traditional concept of perforated panels is revisited and is incorporated with additive manufacturing for the development of a novel microlattice-based sound absorber with additional impact resistance multifunctionality. The structurally optimized microlattice presents excellent broadband absorption with an averaged experimental absorption coefficient of 0.77 across a broad frequency range from 1000 to 6300 Hz. Extensive simulation and experiments reveal absorption mechanisms to be based on viscous flow, thermal and structural damping dissipations while broadband capabilities to be on multiple resonance modes working in tandem. High deformation recovery up to 30% strain is also possible from the strut-based design and viscoelasticity of the base material. Overall, the excellent properties of the microlattice overcome tradeoffs commonly found in conventional absorbers. Additionally, this work aims to present a new paradigm: revisiting old concepts for the developments of novel materials using contemporary methods.

Microlattice Metamaterials with Simultaneous Superior Acoustic and Mechanical Energy Absorption

The advent of 3D printing brought about the possibilities of microlattice metamaterials as advanced materials with the potentials to surpass the functionalities of traditional materials. Sound absorbing materials which are also tough and lightweight are of particular importance as practical engineering materials. There are however a lack of attempts on the study of metamaterials multifunctional for both purposes. Herein, we present four types of face-centered cubic based plate and truss microlattices as novel metamaterials with simultaneous excellent sound and mechanical energy absorption performance. High sound absorption coefficients nearing 1 and high specific energy absorption of 50.3 J g^-1 have been measured. Sound absorption mechanisms of microlattices are proposed to be based on a "cascading resonant cells theory", an extension of the Helmholtz resonance principle that we have conceptualized herein. Characteristics of absorption coefficients are found to be essentially geometry limited by the pore and cavity morphologies. The excellent mechanical properties in turn derive from both the approximate membrane stress state of the plate architecture and the excellent ductility and strength of the base material. Overall, this work presents a new concept on the specific structural design and materials selection for architectured metamaterials with dual sound and mechanical energy absorption capabilities.

3D NiCo-Layered double Hydroxide@Ni nanotube networks as integrated free-standing electrodes for nonenzymatic glucose sensing

Nickel cobalt layered double hydroxide (NiCo-LDH)-based materials have recently emerged as catalysts for important electrochemical applications. However, they frequently suffer from low electrical conductivity and agglomeration, which in turn impairs their performance. Herein, we present a catalyst design based on integrated, self-supported nickel nanotube networks (Ni-NTNWs) loaded with NiCo-LDH nanosheets, which represents a binder-free, hierarchically nanostructured electrode architecture combining continuous conduction paths and openly accessible macropores of low tortuosity with an ultrahigh density of active sites. Similar to macroscale metallic foams, the NTNWs serve as three-dimensionally interconnected, robust frameworks for the deposition of active material, but are structured in the submicron range. Our synthesis is solely based on scalable approaches, namely templating with commercial track-etched membranes, electroless plating, and electrodeposition. Morphological and compositional characterization proved the successful decoration of the inner and outer nanotube surfaces with a conformal NiCo-LDH layer. Ni-NTNW electrodes and hydroxide-decorated variants showed excellent performance in glucose sensing. The highest activity was achieved for the catalyst augmented with NiCo-LDH nanosheets, which surpassed the modification with pure Ni(OH)₂. Despite its low thickness of 20 µm, the optimized catalyst layer provided an outstanding sensitivity of 4.6 mA mM^-1 cm^-2, a low detection limit of 0.2 µM, a fast response time of 5.3 s, high selectivity and stability, and two linear ranges covering four orders of magnitude, up to 2.5 mM analyte. As such, derivatized interconnected metal nano-networks represent a promising design paradigm for highly miniaturized yet effective catalyst electrodes and electrochemical sensors.

Structure-Enhanced Mechanically Robust Graphite Foam with Ultrahigh MnO2 Loading for Supercapacitors

With the fast bloom of flexible electronics and green vehicles, it is vitally important to rationally design and facilely construct customized functional materials with excellent mechanical properties as well as high electrochemical performance. Herein, by utilizing two modern industrial techniques, digital light processing (DLP) and chemical vapor deposition (CVD), a unique 3D hollow graphite foam (HGF) is demonstrated, which shows a periodic porous structure and robust mechanical properties. Finite element analysis (FEA) results confirm that the properly designed gyroidal porous structure provides a uniform stress area and mitigates potential structural failure caused by stress concentrations. A typical HGF can show a high Young's modulus of 3.18 MPa at a low density of 48.2 mg cm^-3. The porous HGF is further covered by active MnO₂ material with a high mass loading of 28.2 mg cm^-2 (141 mg cm^-3), and the MnO₂/HGF electrode still achieves a satisfactory specific capacitance of 260 F g^-1, corresponding to a high areal capacitance of 7.35 F cm^-2 and a high volumetric capacitance of 36.75 F cm^-3. Furthermore, the assembled quasi-solid-state asymmetric supercapacitor also shows remarkable mechanical properties as well as electrochemical performance.

A 3d-printed composite electrode for sustained electrocatalytic oxygen evolution

We report the facile design and fabrication of 3D-printed microstructured electrodes for electrocatalytic oxygen evolution. ABS polymer-based mesh scaffolds are chemically functionalized to enable electroless nickel metal deposition and subsequent catalyst (nickel iron hydroxide) immobilization. The resulting composites show sustained oxygen evolution with low overpotentials and high stability. The modular approach reported enables the scalable on-demand fabrication of microstructured composite electrodes.

Fabricating Mechanically Robust Binder-Free Structured Zeolites by 3D Printing Coupled with Zeolite Soldering: A Superior Configuration for CO2 Capture

3D-printing technology is a promising approach for rapidly and precisely manufacturing zeolite adsorbents with desirable configurations. However, the trade-off among mechanical stability, adsorption capacity, and diffusion kinetics remains an elusive challenge for the practical application of 3D-printed zeolites. Herein, a facile "3D printing and zeolite soldering" strategy is developed to construct mechanically robust binder-free zeolite monoliths (ZM-BF) with hierarchical structures, which can act as a superior configuration for CO2 capture. Halloysite nanotubes are employed as printing ink additives, which serve as both reinforcing materials and precursor materials for integrating ZM-BF by ultrastrong interfacial "zeolite-bonds" subjected to hydrothermal treatment. ZM-BF exhibits outstanding mechanical properties with robust compressive strength up to 5.24 MPa, higher than most of the reported structured zeolites with binders. The equilibrium CO2 uptake of ZM-BF reaches up to 5.58 mmol g-1 (298 K, 1 bar), which is the highest among all reported 3D-printed CO2 adsorbents. Strikingly, the dynamic adsorption breakthrough tests demonstrate the superiority of ZM-BF over commercial benchmark zeolites for flue gas purification and natural gas and biogas upgrading. This work introduces a facile strategy for designing and fabricating high-performance hierarchically structured zeolite adsorbents and even catalysts for practical applications.