Development of 3D printable formulations containing CNT with enhanced electrical properties

Shape-Memory Polymers Based on Carbon Nanotube Composites

For the past two decades, researchers have been exploring the potential benefits of combining shape-memory polymers (SMP) with carbon nanotubes (CNT). By incorporating CNT as reinforcement in SMP, they have aimed to enhance the mechanical properties and improve shape fixity. However, the remarkable intrinsic properties of CNT have also opened up new paths for actuation mechanisms, including electro- and photo-thermal responses. This opens up possibilities for developing soft actuators that could lead to technological advancements in areas such as tissue engineering and soft robotics. SMP/CNT composites offer numerous advantages, including fast actuation, remote control, performance in challenging environments, complex shape deformations, and multifunctionality. This review provides an in-depth overview of the research conducted over the past few years on the production of SMP/CNT composites with both thermoset and thermoplastic matrices, with a focus on the unique contributions of CNT to the nanocomposite's response to external stimuli.

From Unregulated Networks to Designed Microstructures: Introducing Heterogeneity at Different Length Scales in Photopolymers for Additive Manufacturing

Photopolymers have been optimized as protective and decorative coating materials for decades. However, with the rise of additive manufacturing technologies, vat photopolymerization has unlocked the use of photopolymers for three-dimensional objects with new material requirements. Thus, the originally highly cross-linked, amorphous architecture of photopolymers cannot match the expectations for modern materials anymore, revealing the largely unanswered question of how diverse properties can be achieved in photopolymers. Herein, we review how microstructural features in soft matter materials should be designed and implemented to obtain high performance materials. We then translate these findings into chemical design suggestions for enhanced printable photopolymers. Based on this analysis, we have found microstructural heterogenization to be the most powerful tool to tune photopolymer performance. By combining the chemical toolbox for photopolymerization and the analytical toolbox for microstructural characterization, we examine current strategies for physical heterogenization (fillers, inkjet printing) and chemical heterogenization (semicrystalline polymers, block copolymers, interpenetrating networks, photopolymerization induced phase separation) of photopolymers and put them into a material scientific context to develop a roadmap for improving and diversifying photopolymers' performance.

3D-printed extraction devices fabricated from silica particles suspended in acrylate resin

In recent years, there has been an increasing worldwide interest in the use of alternative sample preparation methods. Digital light processing (DLP) is a 3D printing technique based on using UV light to form photo-curable resin layer upon layer, which results in a printed shape. This study explores the application of this technique for the development of novel drug extraction devices in analytical chemistry. A composite material consisting of a photocurable resin and C18-modified silica particles was employed as a sorbent device, demonstrating its effectiveness in pharmaceutical analysis. Apart from estimating optimal printing parameters, microscopic examination of the material surface, and sorbent powder to resin ratio, the extraction procedure was also optimised. Optimisation included the type and amount of sample matrix additives, desorption solvent, sorption and desorption times, and proper number of sorbent devices needed in extraction protocol. To demonstrate this method's applicability for sample analysis, the solid-phase extraction followed by gas chromatography coupled with mass spectrometry (SPE-GC-MS) method was validated for its ability to quantify benzodiazepine-type drugs. This evaluation confirmed good linearity in the concentration range of 50-1000 ng/mL, with R2 values being 0.9932 and 0.9952 for medazepam and diazepam, respectively. Validation parameters proved that the presented method is precise (with values ranging in-between 2.98 %-7.40 %), and accurate (88.81 % to 110.80 %). A negative control was also performed to investigate possible sorption properties of the resin itself, proving that the addition of C18-modified silica particles significantly increases the extraction efficiency and repeatability. The cost-effectiveness of this approach makes it particularly advantageous for single-use scenarios, eliminating the need for time-consuming sorbent-cleaning procedures, common in traditional solid-phase extraction techniques. Future optimisation opportunities include refining sorbent size, shape, and geometry to achieve lower limits of quantification. As a result of these findings, 3D-printed extraction devices can serve as a viable alternative to commercially available SPE or solid-phase microextraction (SPME) protocols for studying new sample preparation approaches.

Recyclable Multifunctional Nanocomposites Based on Carbon Nanotube Reinforced Vitrimers with Shape Memory and Joule Heating Capabilities

The present study focuses on the multifunctional capabilities of carbon nanotube (CNT)-reinforced vitrimers. More specifically, the thermomechanical properties, the Joule effect heating capabilities, the electrical conductivity, the shape memory, and the chemical recycling capacity are explored as a function of the CNT content and the NH2/epoxy ratio. It is observed that the electrical conductivity increases with the CNT content due to a higher number of electrical pathways, while the effect of the NH2/epoxy ratio is not as prevalent. Moreover, the Tg of the material decreases when increasing the NH2/epoxy ratio due to the lower cross-link density, whereas the effect of the CNTs is more complex, in some cases promoting a steric hindrance. The results of Joule heating tests prove the suitability of the proposed materials for resistive heating, reaching average temperatures above 200 °C when applying 100 V for the most electrically conductive samples. Shape memory behavior shows an outstanding shape fixity ratio in every case (around 100%) and a higher shape recovery ratio (95% for the best-tested condition) when decreasing the NH2/epoxy ratio and increasing the CNT content, as both hinder the rearrangement of the dynamic bonds. Finally, the results of the recyclability tests show the ability to regain the nanoreinforcement for their further use. Therefore, from a multifunctional analysis, it can be stated that the proposed materials present promising properties for a wide range of applications, such as Anti-icing and De-icing Systems (ADIS), Joule heating devices for comfort or thermotherapy, or self-deployable structures, among others.

Post-CMOS processing challenges and design developments of CMOS-MEMS microheaters for local CNT synthesis

Carbon nanotubes (CNTs) can be locally grown on custom-designed CMOS microheaters by a thermal chemical vapour deposition (CVD) process to utilize the sensing capabilities of CNTs in emerging micro- and nanotechnology applications. For such a direct CMOS-CNT integration, a key requirement is the development of necessary post-processing steps on CMOS chips for fabricating CMOS-MEMS polysilicon heaters that can locally generate the required CNT synthesis temperatures (~650-900 °C). In our post-CMOS processing, a subtractive fabrication technique is used for micromachining the polysilicon heaters, where the passivation layers in CMOS are used as masks to protect the electronics. For dielectric etching, it is necessary to achieve high selectivity, uniform etching and a good etch rate to fully expose the polysilicon layers without causing damage. We achieved successful post-CMOS processing by developing two-step reactive ion etching (RIE) of the SiO2 dielectric layer and making design improvements to a second-generation CMOS chip. After the dry etching process, CMOS-MEMS microheaters are partially suspended by SiO2 wet etching with minimum damage to the exposed aluminium layers, to obtain high thermal isolation. The fabricated microheaters are then successfully utilized for synthesizing CNTs by a local thermal CVD process. The CMOS post-processing challenges and design aspects to fabricate CMOS-MEMS polysilicon microheaters for such high-temperature applications are detailed in this article. Our developed process for heterogeneous monolithic integration of CMOS-CNT shows promise for wafer-level manufacturing of CNT-based sensors by incorporating additional steps in an already existing foundry CMOS process.

3D printed electronics with nanomaterials

A large variety of printing, deposition and writing techniques have been incorporated to fabricate electronic devices in the last decades. This approach, printed electronics, has gained great interest in research and practical applications and is successfully fuelling the growth in materials science and technology. On the other hand, a new player is emerging, additive manufacturing, called 3D printing, introducing a new capability to create geometrically complex constructs with low cost and minimal material waste. Having such tremendous technology in our hands, it was just a matter of time to combine advances of printed electronics technology for the fabrication of unique 3D structural electronics. Nanomaterial patterning with additive manufacturing techniques can enable harnessing their nanoscale properties and the fabrication of active structures with unique electrical, mechanical, optical, thermal, magnetic and biological properties. In this paper, we will briefly review the properties of selected nanomaterials suitable for electronic applications and look closer at the current achievements in the synergistic integration of nanomaterials with additive manufacturing technologies to fabricate 3D printed structural electronics. The focus is fixed strictly on techniques allowing as much as possible fabrication of spatial 3D objects, or at least conformal ones on 3D printed substrates, while only selected techniques are adaptable for 3D printing of electronics. Advances in the fabrication of conductive paths and circuits, passive components, antennas, active and photonic components, energy devices, microelectromechanical systems and sensors are presented. Finally, perspectives for development with new nanomaterials, multimaterial and hybrid techniques, bioelectronics, integration with discrete components and 4D-printing are briefly discussed.

Chemistry in light-induced 3D printing

In the last few years, 3D printing has evolved from its original niche applications, such as rapid prototyping and hobbyists, towards many applications in industry, research and everyday life. This involved an evolution in terms of equipment, software and, most of all, in materials. Among the different available 3D printing technologies, the light activated ones need particular attention from a chemical point of view, since those are based on photocurable formulations and in situ rapid solidification via photopolymerization. In this article, the chemical aspects beyond the preparation of a formulation for light-induced 3D printing are analyzed and explained, aiming at giving more tools for the development of new photocurable materials that can be used for the fabrication of innovative 3D printable devices.

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Vat photopolymerization-based 3D printing of polymer nanocomposites: current trends and applications

The synthesis and manufacturing of polymer nanocomposites have garnered interest in recent research and development because of their superiority compared to traditionally employed industrial materials. Specifically, polymer nanocomposites offer higher strength, stronger resistance to corrosion or erosion, adaptable production techniques, and lower costs. The vat photopolymerization (VPP) process is a group of additive manufacturing (AM) techniques that provide the benefit of relatively low cost, maximum flexibility, high accuracy, and complexity of the printed parts. In the past few years, there has been a rapid increase in the understanding of VPP-based processes, such as high-resolution AM methods to print intricate polymer parts. The synergistic integration of nanocomposites and VPP-based 3D printing processes has opened a gateway to the future and is soon expected to surpass traditional manufacturing techniques. This review aims to provide a theoretical background and the engineering capabilities of VPP with a focus on the polymerization of nanocomposite polymer resins. Specifically, the configuration, classification, and factors affecting VPP are summarized in detail. Furthermore, different challenges in the preparation of polymer nanocomposites are discussed together with their pre- and post-processing, where several constraints and limitations that hinder their printability and photo curability are critically discussed. The main focus is the applications of printed polymer nanocomposites and the enhancement in their properties such as mechanical, biomedical, thermal, electrical, and magnetic properties. Recent literature, mainly in the past three years, is critically discussed and the main contributing results in terms of applications are summarized in the form of tables. The goal of this work is to provide researchers with a comprehensive and updated understanding of the underlying difficulties and potential benefits of VPP-based 3D printing of polymer nanocomposites. It will also help readers to systematically reveal the research problems, gaps, challenges, and promising future directions related to polymer nanocomposites and VPP processes.

Fabrication of Flexible Wiring with Intrinsically Conducting Polymers Using Blue-Laser Microstereolithography

Recently, flexible devices using intrinsically conductive polymers, particularly poly(3,4-ethylenedioxythiophene) (PEDOT), have been extensively investigated. However, most flexible wiring fabrication methods using PEDOT are limited to two-dimensional (2D) fabrication. In this study, we fabricated three-dimensional (3D) wiring using the highly precise 3D printing method of stereolithography. Although several PEDOT fabrication methods using 3D printing systems have been studied, few have simultaneously achieved both high conductivity and precise accuracy. In this study, we review the post-fabrication process, particularly the doping agent. Consequently, we successfully fabricated wiring with a conductivity of 16 S cm^-1. Furthermore, flexible wiring was demonstrated by modeling the fabricated wiring on a polyimide film with surface treatment and creating a three-dimensional fabrication object.

Applications, fluid mechanics, and colloidal science of carbon-nanotube-based 3D printable inks

Additive manufacturing, also known as 3D printing (3DP), is a novel and developing technology, which has a wide range of industrial and scientific applications. This technology has continuously progressed over the past several decades, with improvement in productivity, resolution of the printed features, achievement of more and more complex shapes and topographies, scalability of the printed components and devices, and discovery of new printing materials with multi-functional capabilities. Among these newly developed printing materials, carbon-nanotubes (CNT) based inks, with their remarkable mechanical, electrical, and thermal properties, have emerged as an extremely attractive option. Various formulae of CNT-based ink have been developed, including CNT-nano-particle inks, CNT-polymer inks, and CNT-based non-nanocomposite inks (i.e., CNT ink that is not in a form where CNT particles are suspended in a polymer matrix). Various types of sensors as well as soft and smart electronic devices with a multitude of applications have been fabricated with CNT-based inks by employing different 3DP methods including syringe printing (SP), aerosol-jet printing (AJP), fused deposition modeling (FDM), and stereolithography (SLA). Despite such progress, there is inadequate literature on the various fluid mechanics and colloidal science aspects associated with the printability and property-tunability of nanoparticulate inks, specifically CNT-based inks. This review article, therefore, will focus on the formulation, dispersion, and the associated fluid mechanics and the colloidal science of 3D printable CNT-based inks. This article will first focus on the different examples where 3DP has been employed for printing CNT-based inks for a multitude of applications. Following that, we shall highlight the various key fluid mechanics and colloidal science issues that are central and vital to printing with such inks. Finally, the article will point out the open existing challenges and scope of future work on this topic.

Lignin as a High-Value Bioaditive in 3D-DLP Printable Acrylic Resins and Polyaniline Conductive Composite

With increasing environmental awareness, lignin will play a key role in the transition from the traditional materials industry towards sustainability and Industry 4.0, boosting the development of functional eco-friendly composites for future electronic devices. In this work, a detailed study of the effect of unmodified lignin on 3D printed light-curable acrylic composites was performed up to 4 wt.%. Lignin ratios below 3 wt.% could be easily and reproducibly printed on a digital light processing (DLP) printer, maintaining the flexibility and thermal stability of the pristine resin. These low lignin contents lead to 3D printed composites with smoother surfaces, improved hardness (Shore A increase ~5%), and higher wettability (contact angles decrease ~19.5%). Finally, 1 wt.% lignin was added into 3D printed acrylic resins containing 5 wt.% p-toluensulfonic doped polyaniline (pTSA-PANI). The lignin/pTSA-PANI/acrylic composite showed a clear improvement in the dispersion of the conductive filler, reducing the average surface roughness (R_a) by 61% and increasing the electrical conductivity by an order of magnitude (up to 10^-6 S cm^-1) compared to lignin free PANI composites. Thus, incorporating organosolv lignin from wood industry wastes as raw material into 3D printed photocurable resins represents a simple, low-cost potential application for the design of novel high-valued, bio-based products.

Injection continuous liquid interface production of 3D objects

In additive manufacturing, it is imperative to increase print speeds, use higher-viscosity resins, and print with multiple different resins simultaneously. To this end, we introduce a previously unexplored ultraviolet-based photopolymerization three-dimensional printing process. The method exploits a continuous liquid interface-the dead zone-mechanically fed with resin at elevated pressures through microfluidic channels dynamically created and integral to the growing part. Through this mass transport control, injection continuous liquid interface production, or iCLIP, can accelerate printing speeds to 5- to 10-fold over current methods such as CLIP, can use resins an order of magnitude more viscous than CLIP, and can readily pattern a single heterogeneous object with different resins in all Cartesian coordinates. We characterize the process parameters governing iCLIP and demonstrate use cases for rapidly printing carbon nanotube-filled composites, multimaterial features with length scales spanning several orders of magnitude, and lattices with tunable moduli and energy absorption.

Enhanced mechanical performance of mSLA-printed biopolymer nanocomposites due to phase functionalization

Functionalized phases can effectively increase the mechanical properties of nanocomposites through interfacial bonding. This work demonstrates masked stereolithography (mSLA) of biopolymer-based nanocomposites and the improvement of their mechanical properties by the functionalization of both polymer matrix and nanoparticles with methacrylate groups. 3D printable nanocomposite inks were prepared from plant-derived acrylated epoxidized soybean oil (AESO), polyethylene glycol diacrylate (PEGDA), and nano-hydroxyapatite (nHA). Both AESO and nHA were further functionalized with additional methacrylate groups. We hypothesized that the additional functionalization of AESO and surface functionalization of nHA would improve the tensile strength and fracture toughness of these nanocomposites by increasing the degree of crosslinking and the strength of the interface between the matrix and nanoparticles. Curing efficiency, rheology, and print-fidelity of the nanocomposites were evaluated. Mechanical test specimens were prepared by mSLA-based 3D printing. Tensile mechanical properties, Poisson's ratio, and Mode-I fracture toughness were measured by following ASTM standards. Fracture surfaces of the tested specimens were studied using scanning electron microscopy. Thermomechanical behavior, especially glass transition temperature (T_g), was studied using dynamic mechanical analysis (DMA). Functionalized AESO (mAESO) improved rheological, tensile, and fracture mechanical properties. For instance, by replacing AESO with mAESO, tensile strength, Young's modulus, fracture toughness (K_1c), and T_g increased by 33%, 53%, 40%, and 38% respectively. In addition, the combination of both functionalized nHA and mAESO improved the fracture toughness of the 10% volume fraction nHA nanocomposites but made them less extensible presumably due to reduced chain mobility due to greater crosslinking.

Electroconductive Photo-Curable PEGDA-Gelatin/PEDOT:PSS Hydrogels for Prospective Cardiac Tissue Engineering Application

Electroconductive hydrogels (ECHs) have attracted interest for tissue engineering applications due to their ability to promote the regeneration of electroactive tissues. Hence, ECHs with tunable electrical and mechanical properties, bioactivity, biocompatibility and biodegradability are demanded. In this work, ECHs based on photo-crosslinked blends of polyethylene glycol diacrylate (PEGDA) and gelatin with different PEGDA:gelatin ratios (1:1, 1.5:1 and 2:1 wt./wt.), and containing poly (3,4-ethylenedioxythiophene):poly (styrene sulfonate) (PEDOT:PSS) (0.0, 0.1, 0,3 and 0.5% w/v%) were prepared. Main novelty was the use of gelatin as bioactive component and co-initiator in the photo-crosslinking process, leading to its successful incorporation in the hydrogel network. Physical properties could be modulated by the initial PEGDA:gelatin weight ratio. Pristine hydrogels with increasing PEGDA:gelatin ratio showed: (i) an increasing compressive elastic modulus from 5 to 28 kPa; (ii) a decreasing weight loss from 62% to 43% after 2 weeks incubation in phosphate buffered saline at 37°C; (iii) reduced crosslinking time; (iv) higher crosslinking density and (v) lower water absorption. The addition of PEDOT:PSS in the hydrogels reduced photo-crosslinking time (from 60 to 10 s) increasing their surface and bulk electrical properties. Finally, in vitro tests with human cardiac fibroblasts showed that hydrogels were cytocompatible and samples with 1.5:1 initial PEGDA:gelatin ratio promoted the highest cell adhesion at 24 h. Results from this work suggested the potential of electroconductive photo-curable PEGDA-gelatin/PEDOT:PSS hydrogels for prospective cardiac tissue engineering applications.

Development of 3D ZnO-CNT Support Structures Impregnated with Inorganic Salts

Carbon-based materials are promising candidates for enhancing thermal properties of phase change materials (PCMs) without lowering its energy storage capacity. Nowadays, researchers are trying to find a proper porous structure as PCMs support for thermal energy storage applications. In this context, the main novelty of this paper consists in using a ZnO-CNT-based nanocomposite powder, prepared by an own hydrothermal method at high pressure, to obtain porous 3D printed support structures with embedding capacity of PCMs. The morphology of 3D structures, before and after impregnation with three PCMs inorganic salts (NaNO₃, KNO₃ and NaNO₃:KNO₃ mixture (1:1 vol% saturated solution) was investigated by scanning electron microscopy coupled with energy-dispersive X-ray spectroscopy (SEM-EDX). For structure impregnated with nitrates mixture, SEM cross-section morphology suggest that the inorganic salts impregnation started into micropores, continuing with the covering of the 3D structure surface and epitaxial growing of micro/nanostructured crystals, which led to reducing the distance between the structural strands. The variation of melting/crystallization points and associated enthalpies of impregnated PCMs and their stability during five repeated thermal cycles were studied by differential scanning calorimetry (DSC) and simultaneous DSC-thermogravimetry (DSC-TGA). From the second heating-cooling cycle, the 3D structures impregnated with NaNO₃ and NaNO₃-KNO₃ mixture are thermally stable.

Advances in Digital Light Processing of Hydrogels

Hydrogels, three-dimensional (3D) networks of hydrophilic polymers formed in water, are a significant type of soft matter used in fundamental and applied sciences. Hydrogels are of particular interest for biomedical applications, owing to their soft elasticity and good biocompatibility. However, the high water content and soft nature of hydrogels often make it difficult to process them into desirable solid forms. The development of 3D printing (3DP) technologies has provided opportunities for the manufacturing of hydrogels, by adopting a freeform fabrication method. Owing to its high printing speed and resolution, vat photopolymerization 3DP has recently attracted considerable interest for hydrogel fabrication, with digital light processing (DLP) becoming a widespread representative technique. Whilst acknowledging that other types of vat photopolymerization 3DP have also been applied for this purpose, we here only focus on DLP and its derivatives. In this review, we first comprehensively outline the most recent advances in both materials and fabrication, including the adaptation of novel hydrogel systems and advances in processing (e.g., volumetric printing and multimaterial integration). Secondly, we summarize the applications of hydrogel DLP, including regenerative medicine, functional microdevices, and soft robotics. To the best of our knowledge, this is the first time that either of these specific review focuses has been adopted in the literature. More importantly, we discuss the major challenges associated with hydrogel DLP and provide our perspectives on future trends. To summarize, this review aims to aid and inspire other researchers investigatng DLP, photocurable hydrogels, and the research fields related to them.

Characterization 0.1 wt.% Nanomaterial/Photopolymer Composites with Poor Nanomaterial Dispersion: Viscosity, Cure Depth and Dielectric Properties

Notably, 3D printing techniques such as digital light processing (DLP) have the potential for the cost-effective and flexible production of polymer-based piezoelectric composites. To improve their properties, conductive nanomaterials can be added to the photopolymer to increase their dielectric properties. In this study, the microstructure, viscosity, cure depth, and dielectric properties of ultraviolet (UV) light curable 0.1 wt.% nanomaterial/photopolymer composites are investigated. The composites with multi-walled carbon nanotubes (MWCNTs), graphene nanoplatelets (GNPs), and carbon black (CB) are pre-dispersed in different solvents (acetone, isopropyl alcohol, and ethanol) before adding photopolymer and continuing dispersion. For all prepared suspensions, a reduction in viscosity is observed, which is favorable for 3D printing. In contrast, the addition of 0.1 wt.% nanomaterials, even with poor dispersion, leads to curing depth reduction up to 90% compared to pristine photopolymer, where the nanomaterial dispersion is identified as a contributing factor. The formulation of MWCNTs dispersed in ethanol is found to be the most promising for increasing the dielectric properties. The post-curing of all composites leads to charge immobility, resulting in decreased relative permittivity.

mSLA-based 3D printing of acrylated epoxidized soybean oil - nano-hydroxyapatite composites for bone repair

Structural bone allografts are used to treat critically sized segmental bone defects (CSBDs) as such defects are too large to heal naturally. Development of biomaterials with competent mechanical properties that can also facilitate new bone formation is a major challenge for CSBD repair. 3D printed synthetic bone grafts are a possible alternative to structural allografts if engineered to provide appropriate structure with sufficient mechanical properties. In this work, we fabricated a set of novel nanocomposite biomaterials consisting of acrylated epoxidized soybean oil (AESO), polyethylene glycol diacrylate (PEGDA) and nanohydroxyapatite (nHA) by using masked stereolithography (mSLA)-based 3D printing. The nanocomposite inks possess suitable rheological properties and good printability to print complex, anatomically-precise, 'by design' grafts. The addition of nHA to the AESO/PEGDA resin improved the tensile strength and fracture toughness of the mSLA printed nanocomposites, presumably due to small-scale reinforcement. By adding 10 vol% nHA, tensile strength, modulus and fracture toughness (K_Ic) were increased to 30.8 ± 1.2 MPa (58% increase), 1984.4 ± 126.7 MPa (144% increase) and 0.6 ± 0.1 MPa·m^1/2 (42% increase), respectively (relative to the pure resin). The nanocomposites did not demonstrate significant hydrolytic, enzymatic or oxidative degradation when incubated for 28 days, assuring chemical and mechanical stability at early stages of implantation. Apatite nucleated and covered the nanocomposite surfaces within 7 days of incubation in simulated body fluid. Good viability and proliferation of differentiated MC3T3-E1 osteoblasts were also observed on the nanocomposites. Taken all together, our nanocomposites demonstrate excellent bone-bioactivity and potential for bone defect repair.

Printability Study of a Conductive Polyaniline/Acrylic Formulation for 3D Printing

There is need for developing novel conductive polymers for Digital Light Processing (DLP) 3D printing. In this work, photorheology, in combination with Jacobs working curves, efficaciously predict the printability of polyaniline (PANI)/acrylate formulations with different contents of PANI and photoinitiator. The adjustment of the layer thickness according to cure depth values (C_d) allows printing of most formulations, except those with the highest gel point times determined by photorheology. In the working conditions, the maximum amount of PANI embedded within the resin was ≃3 wt% with a conductivity of 10^-5 S cm^-1, three orders of magnitude higher than the pure resin. Higher PANI loadings hinder printing quality without improving electrical conductivity. The optimal photoinitiator concentration was found between 6 and 7 wt%. The mechanical properties of the acrylic matrix are maintained in the composites, confirming the viability of these simple, low-cost, conductive composites for applications in flexible electronic devices.

3D Printing Materials for Soft Robotics

Soft robotics is a growing field of research, focusing on constructing motor-less robots from highly compliant materials, some are similar to those found in living organisms. Soft robotics has a high potential for applications in various fields such as soft grippers, actuators, and biomedical devices. 3D printing of soft robotics presents a novel and promising approach to form objects with complex structures, directly from a digital design. Here, recent developments in the field of materials for 3D printing of soft robotics are summarized, including high-performance flexible and stretchable materials, hydrogels, self-healing materials, and shape memory polymers, as well as fabrication of all-printed robots (multi-material printing, embedded electronics, untethered and autonomous robotics). The current challenges in the fabrication of 3D printed soft robotics, including the materials available and printing abilities, are presented and the recent activities addressing these challenges are also surveyed.

Analysis of strain sensitivity under flexural load of 3D printed carbon nanotube-doped epoxy circuits

A 3D printing system able to print circuits of conductive epoxy resin doped with carbon nanotubes (CNTs) is proposed. Different simple circuits, more specifically lines and strain gauge patterns, made of resins reinforced with 0.3, 0.5, 0.8 and 1 wt% of CNTs were printed on the surface of glass fiber laminates. It was observed that increasing the CNT content reduced the wettability of the printed circuits on the glass fiber substrate. In every case the contact angle was far below 90°. Furthermore, the strain sensing capabilities were analyzed under a flexural load. The results showed that the sensitivity increased with CNT content (with gauge factor values from 1.5 to 2.5) as a result of the prevalent effect of well-dispersed areas due to a reduction in the tunneling distance. On the other hand, the strain gauges showed a lower sensitivity (around 20%-40% less, depending on the condition) compared with line circuits due to localized compressive effects. Furthermore, good repeatability of the strain sensors was proved during cycling tests, with similar baseline and peak values for the electrical resistance in each cycle. Therefore, the proposed materials have a high potential for applications in structural health monitoring.

Complex Geometry Strain Sensors Based on 3D Printed Nanocomposites: Spring, Three-Column Device and Footstep-Sensing Platform

Electromechanical sensing devices, based on resins doped with carbon nanotubes, were developed by digital light processing (DLP) 3D printing technology in order to increase design freedom and identify new future and innovative applications. The analysis of electromechanical properties was carried out on specific sensors manufactured by DLP 3D printing technology with complex geometries: a spring, a three-column device and a footstep-sensing platform based on the three-column device. All of them show a great sensitivity of the measured electrical resistance to the applied load and high cyclic reproducibility, demonstrating their versatility and applicability to be implemented in numerous items in our daily lives or in industrial devices. Different types of carbon nanotubes—single-walled, double-walled and multi-walled CNTs (SWCNTs, DWCNTs, MWCNTs)—were used to evaluate the effect of their morphology on electrical and electromechanical performance. SWCNT- and DWCNT-doped nanocomposites presented a higher T_g compared with MWCNT-doped nanocomposites due to a lower UV light shielding effect. This phenomenon also justifies the decrease of nanocomposite T_g with the increase of CNT content in every case. The electromechanical analysis reveals that SWCNT- and DWCNT-doped nanocomposites show a higher electromechanical performance than nanocomposites doped with MWCNTs, with a slight increment of strain sensitivity in tensile conditions, but also a significant strain sensitivity gain at bending conditions.

Thermomechanical Multifunctionality in 3D-Printed Polystyrene-Boron Nitride Nanotubes (BNNT) Composites

In this work, polystyrene (PS) and boron nitrides nanotubes (BNNT) composites were fabricated, prepared, and characterized using modified direct mixing and sonication processes. The polymer composites were extruded into filaments (BNNTs at 10 wt. %) for 3D printing, utilizing the fused deposition modeling (FDM) technique to fabricate parts for mechanical and thermal applications. Using a direct mixing process, we found that the thermal conductivity and the mechanical strength of the PS-BNNT composite were respectively four times and two times higher compared to the sonication method. The thermal stability and glass transition temperatures were positively affected. A 2D microstructural mechanical entanglement model captured the exact geometry of the nanotubes using the MultiMechanics software, and the performance of the additive manufactured (AM) PS-BNNT composites part for thermomechanical application was simulated in COMSOL. The modified direct mixing process for PS-BNNT, which affects morphology, proved to be effective in achieving better interfacial bonding, indicating that BNNTs are promising fillers for improving thermal and mechanical properties, and are applicable for thermal management and electronic packaging.

3D Printing of PDMS-Like Polymer Nanocomposites with Enhanced Thermal Conductivity: Boron Nitride Based Photocuring System

This study demonstrates the possibility of forming 3D structures with enhanced thermal conductivity (k) by vat printing a silicone-acrylate based nanocomposite. Polydimethylsiloxane (PDSM) represent a common silicone-based polymer used in several applications from electronics to microfluidics. Unfortunately, the k value of the polymer is low, so a composite is required to be formed in order to increase its thermal conductivity. Several types of fillers are available to reach this result. In this study, boron nitride (BN) nanoparticles were used to increase the thermal conductivity of a PDMS-like photocurable matrix. A digital light processing (DLP) system was employed to form complex structures. The viscosity of the formulation was firstly investigated; photorheology and attenuate total reflection Fourier-transform infrared spectroscopy (ATR-FTIR) analyses were done to check the reactivity of the system that resulted as suitable for DLP printing. Mechanical and thermal analyses were performed on printed samples through dynamic mechanical thermal analysis (DMTA) and tensile tests, revealing a positive effect of the BN nanoparticles. Morphological characterization was performed by scanning electron microscopy (SEM). Finally, thermal analysis demonstrated that the thermal conductivity of the material was improved, maintaining the possibility of producing 3D printable formulations.

An Overview of Additive Manufacturing of Polymers and Associated Composites

Additive manufacturing is rapidly evolving and opening new possibilities for many industries. This article gives an overview of the current status of additive manufacturing with polymers and polymer composites. Various types of reinforcements in polymers and architectured cellular material printing including the auxetic metamaterials and the triply periodic minimal surface structures are discussed. Finally, applications, current challenges, and future directions are highlighted here.

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

Only a few 3D-printing techniques are able to process ceramic materials and exploit successfully the capabilities of additive manufacturing of sintered ceramic parts. In this work, a new two component binder system, consisting of polyethyleneglycol and polyvinylbutyral, as well stearic acid as surfactant, was filled with submicron sized alumina up to 55 vol.% and used in fused filament fabrication (FFF) for the first time. The whole process chain, as established in powder injection molding of ceramic parts, starting with material selection, compounding, measurement of shear rate and temperature dependent flow behavior, filament fabrication, as well as FFF printing. A combination of solvent pre-debinding with thermal debinding and sintering at a reduced maximum temperature due to the submicron sized alumina and the related enhanced sinter activity, enabled the realization of alumina parts with complex shape and sinter densities around 98 % Th. Finally the overall shrinkage of the printed parts were compared with similar ones obtained by micro ceramic injection molding.

Recent advances in additive manufacturing of engineering thermoplastics: challenges and opportunities

There are many limitations within three-dimensional (3D) printing that hinder its adaptation into industries such as biomedical, cosmetic, processing, automotive, aerospace, and electronics. The disadvantages of 3D printing include the inability of parts to function in weight-bearing applications, reduced mechanical performance from anisotropic properties of printed products, and limited intrinsic material performances such as flame retardancy, thermal stability, and/or electrical conductivity. Many of these shortcomings have prevented the adaptation of 3D printing into product development, especially with few novel researched materials being sold commercially. In many cases, high-performance engineering thermoplastics (ET) provide a basis for increased thermal and mechanical performances to address the shortcomings or limitations of both selective laser sintering and extrusion 3D printing. The first strategy to combat these limitations is to fabricate blends or composites. Novel printing materials have been implemented to reduce anisotropic properties and losses in strength. Additives such as flame retardants generate robust materials with V0 flame retardancy ratings, and compatibilizers can improve thermal or dimensional stability. To serve the electronic industry better, the addition of carbon black at only 4 wt%, to an ET matrix has been found to improve the electrical conductivity by five times the magnitude. Surface modifications such as photopolymerization have improved the usability of ET in automotive applications, whereas the dynamic chemical processes increased the biocompatibility of ET for medical device materials. Thermal resistant foam from polyamide 12 and fly ash spheres were researched and fabricated as possible insulation materials for automotive industries. These works and others have not only generated great potential for additive manufacturing technologies, but also provided solutions to critical challenges of 3D printing.

Materials Testing for the Development of Biocompatible Devices through Vat-Polymerization 3D Printing

Light-based 3D printing techniques could be a valuable instrument in the development of customized and affordable biomedical devices, basically for high precision and high flexibility in terms of materials of these technologies. However, more studies related to the biocompatibility of the printed objects are required to expand the use of these techniques in the health sector. In this work, 3D printed polymeric parts are produced in lab conditions using a commercial Digital Light Processing (DLP) 3D printer and then successfully tested to fabricate components suitable for biological studies. For this purpose, different 3D printable formulations based on commercially available resins are compared. The biocompatibility of the 3D printed objects toward A549 cell line is investigated by adjusting the composition of the resins and optimizing post-printing protocols; those include washing in common solvents and UV post-curing treatments for removing unreacted and cytotoxic products. It is noteworthy that not only the selection of suitable materials but also the development of an adequate post-printing protocol is necessary for the development of biocompatible devices.

Recent Trends in Applying Rrtho-Nitrobenzyl Esters for the Design of Photo-Responsive Polymer Networks

Polymers with light-responsive groups have gained increased attention in the design of functional materials, as they allow changes in polymers properties, on demand, and simply by light exposure. For the synthesis of polymers and polymer networks with photolabile properties, the introduction o-nitrobenzyl alcohol (o-NB) derivatives as light-responsive chromophores has become a convenient and powerful route. Although o-NB groups were successfully exploited in numerous applications, this review pays particular attention to the studies in which they were included as photo-responsive moieties in thin polymer films and functional polymer coatings. The review is divided into four different sections according to the chemical structure of the polymer networks: (i) acrylate and methacrylate; (ii) thiol-click; (iii) epoxy; and (iv) polydimethylsiloxane. We conclude with an outlook of the present challenges and future perspectives of the versatile and unique features of o-NB chemistry.

Influence of the Degree of Cure in the Bulk Properties of Graphite Nanoplatelets Nanocomposites Printed via Stereolithography

In this work, we report on the fabrication via stereolithography (SLA) of acrylic-based nanocomposites using graphite nanoplatelets (GNPs) as an additive. GNPs are able to absorb UV-Vis radiation, thus blocking partial or totally the light path of the SLA laser. Based on this, we identified a range of GNP concentrations below 2.5 wt %, where nanocomposites can be successfully printed. We show that, even though GNP is well-dispersed along the polymeric matrix, nanocomposites presented lower degrees of cure and therefore worse mechanical properties when compared with pristine resin. However, a post-processing at 60 °C with UV light for 1 h eliminates this difference in the degree of cure, reaching values above 90% in all cases. In these conditions, the tensile strength is enhanced for 0.5 wt % GNP nanocomposites, while the stiffness is increased for 0.5-1.0 wt % GNP nanocomposites. Finally, we also demonstrate that 2.5 wt % GNP nanocomposites possess characteristic properties of semiconductors, which allows them to be used as electrostatic dispersion materials.

Mechanical and Strain-Sensing Capabilities of Carbon Nanotube Reinforced Composites by Digital Light Processing 3D Printing Technology

Mechanical and strain sensing capabilities of carbon nanotube (CNT) reinforced composites manufactured by digital light processing (DLP) 3D printing technology have been studied. Both CNT content and a post-curing treatment effects have been analyzed. It has been observed that post-curing treatment has a significant influence on mechanical properties, with an increase of Young’s modulus and glass transition temperature whereas their effect in electrical properties is not so important. Furthermore, the strain sensing tests show a linear response of electrical resistance with applied strain, with higher values of sensitivity when decreasing CNT content due to a higher interparticle distance. Moreover, the electrical sensitivity of bending tests is significantly lower than in tensile ones due to the compression subjected face effect. Therefore, the good gauge factor values (around 2–3) and the high linear response proves the applicability of the proposed nanocomposites in structural health monitoring applications.

Hierarchical ordering in light-triggered additive manufacturing

Herein, recent developments in the 3D printing of materials with structural hierarchy and their future prospects are reviewed. It is shown that increasing the extent of ordering, is essential to access novel properties and functionalities.

Photoinitiators derived from natural product scaffolds: monochalcones in three-component photoinitiating systems and their applications in 3D printing

Design of new photoinitiators based on natural Chalcone scaffold.

Design of Iodonium Salts for UV or Near-UV LEDs for Photoacid Generator and Polymerization Purposes

Iodonium salts are well established photoacid generators, cationic photoinitiators, as well as additives commonly used in photoredox catalytic cycles. However, as a strong limitation, iodonium salts are characterized by low light absorption properties for λ > 300 nm so that these latter cannot be activated with cheap, safe, and eco-friendly near UV or even visible light emitting diodes (LEDs). To overcome this drawback, the covalent linkage of an iodonium salt to a chromophore absorbing at longer wavelength is actively researched. With aim at red-shifting the absorption spectrum of the iodonium salt, the synthesis of new compounds combining within a unique chemical structure both the chromophore (here the naphthalimide scaffold) and the iodonium salt is presented. By mean of this strategy, a polymerization could be initiated at 365 nm with the modified iodonium salts whereas no polymerization could be induced with the benchmark iodonium salt i.e., Speedcure 938 at this specific wavelength. To examine the effect of the counter-anion on the photoinitiating ability of these different salts, five different counter-anions were used. Comparison between the different anions revealed the bis(trifluoromethane)sulfonimide salt to exhibit the best photoinitiating ability in both the free radical polymerization of acrylates and the cationic polymerization of epoxides. To support the experimental results, molecular orbital calculations have been carried out. By theoretical calculations, the initiating species resulting from the photocleavage of the iodonium salts could be determined. The cleavage selectivity and the photochemical reactivity of the new iodoniums are also discussed.

Fabrication of High Permittivity Resin Composite for Vat Photopolymerization 3D Printing: Morphology, Thermal, Dynamic Mechanical and Dielectric Properties

The formulation of a high dielectric permittivity ceramic/polymer composite feedstock for daylight vat photopolymerization 3D printing (3DP) is demonstrated, targeting 3DP of devices for microwave and THz applications. The precursor is composed of a commercial visible light photo-reactive polymer (VIS-curable photopolymer) and dispersed titanium dioxide (TiO2, TO) ceramic nano-powder or calcium copper titanate (CCT) micro-powder. To provide consistent 3DP processing from the formulated feedstocks, the carefully chosen dispersant performed the double function of adjusting the overall viscosity of the photopolymer and provided good matrix-to-filler bonding. Depending on the ceramic powder content, the optimal viscosities for reproducible 3DP with resolution better than 100 µm were η(TO) = 1.20 ± 0.02 Pa.s and η (CCT) = 0.72 ± 0.05 Pa.s for 20% w/v TO/resin and 20% w/v CCT/resin composites at 0.1 s-1 respectively, thus showing a significant dependence of the "printability" on the dispersed particle sizes. The complex dielectric properties of the as-3D printed samples from pure commercial photopolymer and the bespoke ceramic/photopolymer mixes are investigated at 2.5 GHz, 5 GHz, and in the 12-18 GHz frequency range. The results show that the addition of 20% w/v of TO and CCT ceramic powder to the initial photopolymer increased the real part of the permittivity of the 3DP composites from ε' = 2.7 ± 0.02 to ε'(TO) = 3.88 ± 0.02 and ε'(CCT) = 3.5 ± 0.02 respectively. The present work can be used as a guideline for high-resolution 3DP of structures possessing high-ε.

Blue Laser Projection Printing of Conductive Complex 2D and 3D Metallic Structures from Photosensitive Precursors

Photosensitive precursors are developed for the printing of 2D and 3D conductive structures via blue laser projection printing. With the assistance of a photosensitizer, metal nanoparticles can be efficiently photosynthesized under laser irradiation of low light intensity (45-290 mW cm^-2). By projecting well-defined laser patterns on the precursor, corresponding 2D metal structures with the finest line of about 50 μm can be formed on various substrates including flexible polymer thin films, curved substrates, and ground glass. Moreover, complex 3D objects with nanoparticles embedded in the polymeric matrix are constructed via 3D printing combining photoreduction of the metal precursor and photopolymerization of resin. The as-prepared structures exhibit promising conductivities after sintering (in the order of magnitude of 10⁶ S m^-1). A possible mechanism of photochemical synthesis of metal nanoparticles upon exposure to blue laser is proposed. The high efficiency and low cost of the technique, the complexity of the structures prepared, and the applicability to various substrates and metals (including silver, gold, and palladium) promise practical applications of this approach in the printed electronics industry.

Antimicrobial Thiol-ene-acrylate Photosensitive Resins for DLP 3D Printing

Designing digital light processing (DLP) 3D printable photosensitive resins with antibacterial properties is especially vital because of their potential applications in various biomedical fields. In this contribution, a thiol-ene-acrylate ternary system with reduced volume shrinkage and fast photopolymerization rate was chosen as the antibacterial 3D printing matrix resin. Two quaternary ammonium salt-type antibacterial agents (QAC and SH-QAC) with different molecular weight were designed and prepared, which can participate in the curing of matrix resin to achieve contact antibacterial effect. The effects of antibacterial agent content on the photopolymerization kinetics and on thermal and mechanical properties were discussed in detail. When the amount of added QAC is 4wt%, the antibacterial rate is almost 100% for Escherichia coli and Staphylococcus aureus, and when the amount of SH-QAC is 10wt%, the antibacterial rate against S. aureus is also essentially 100%. Both antibacterial photosensitive resins have been successfully applied in DLP technology to fabricate tooth model with high precision.

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

In this work, the plating of high-quality amorphous nickel-phosphorous coating with low resistivity of 0.45 µΩ m (298 K) on complex 3D printed polymeric structures with high uniformity is reported. Such a polymer metallization results in an effective conductivity of 4.7 × 104 S m-1. This process also allows flexible structures to maintain their flexibility along with the conductivity. Octet-truss structures with nickel-iron-(oxo) hydroxide nanosheets electrodeposited onto further displays excellent water-splitting performance as catalytic electrodes, i.e., in KOH (1 m, aq), a low oxygen evolution reaction (OER) overpotential of 197 mV at 10 mA cm-2 and Tafel slope of 51 mV dec-1. Using this light-weight electrode with high specific area, strength, and corrosion resistance properties, a fully functional water-splitting system is designed and fabricated through the concentric integration of 3D printed components. A dense polymeric mesh implemented is also demonstrated as an effective separator of hydrogen and oxygen bubbles in this system.

Conductive nanomaterials for 2D and 3D printed flexible electronics

This review describes recent developments in the field of conductive nanomaterials and their application in 2D and 3D printed flexible electronics, with particular emphasis on inks based on metal nanoparticles and nanowires, carbon nanotubes, and graphene sheets. We present the basic properties of these nanomaterials, their stabilization in dispersions, formulation of conductive inks and formation of conductive patterns on flexible substrates (polymers, paper, textile) by using various printing technologies and post-printing processes. Applications of conductive nanomaterials for fabrication of various 2D and 3D electronic devices are also briefly discussed.

3D Printing of Poly(propylene fumarate) Oligomers: Evaluation of Resin Viscosity, Printing Characteristics and Mechanical Properties

Complex three-dimensional (3D) pore geometries, useful for tissue engineering scaffolds, can be fabricated via photo-crosslinking of resorbable poly(propylene fumarate) (PPF) resins using stereolithography (SLA) and/or continuous digital light processing (cDLP) methods. Physico-chemical parameters inherent to 3D printable resin design, include viscosity, polymer concentration, degree of polymerization, and resin printing temperature. We report here on our study of these parameters and their influence the cDLP 3D printing process and the resulting mechanical properties. A series of PPF oligomers were synthesized by the ring-opening copolymerization (ROCOP) of maleic anhydride and propylene oxide followed by a base-catalyzed isomerization. The resin viscosities were measured as a function of number-average molecular mass ([Formula: see text]) of the PPF oligomers (1.1, 1.7 and 2.0 kDa), concentrations of PPF in the reactive diluent diethyl fumarate (DEF) (50 and 75 wt %) and resin temperature (25 to 55 °C). The zero-shear viscosity (η₀) of the resins was found to be temperature-dependent and follow a linear Arrhenius relationship. Tensile tests demonstrated mechanical properties within the range of trabecular bone, with the ultimate strength at break above 15 MPa and elastic moduli between 178 and 199 MPa.

3D Printing with the Commercial UV-Curable Standard Blend Resin: Optimized Process Parameters towards the Fabrication of Tiny Functional Parts

Stereolithography 3D printing is today recognized as an effective rapid prototyping technique in the field of polymeric materials, which represents both the strengths and the weaknesses of this technique. The strengths relate to their easy handling and the low energy required for processing, which allow for the production of structures down to the sub-micrometric scale. The weaknesses are a result of the relatively poor mechanical properties. Unfortunately, the choice of the right material is not sufficient, as the printing parameters also play a crucial role. For this reason, it is important to deepen and clarify the effect of different printing conditions on final product characteristics. In this paper, the behavior of commercial Standard Blend (ST Blend) acrylic resin printed with stereolithography (SL) apparatus is reported, investigating the influence of printing parameters on both the tensile properties of the printed parts and the build accuracy. Twenty-four samples were printed under different printing conditions, then dimensional analyses and tensile tests were performed. It was possible to find out the optimum printing setup to obtain the best result in terms of mechanical resistance and printing accuracy for this kind of resin. Finally, a micrometric spring was printed under the optimal conditions to demonstrate the possibility of printing accurate and tiny parts with the commercial and inexpensive STBlend resin.

Thiol–yne chemistry for 3D printing: exploiting an off-stoichiometric route for selective functionalization of 3D objects

An alkyne monomer, bis(propargyl) fumarate, is synthesized and mixed to a thiol monomer to produce DLP-3D printable formulations. Using off-stoichiometric formulations it is possible to print functionalizable objects.

Poly(propylene fumarate) stars, using architecture to reduce the viscosity of 3D printable resins

Additive manufacturing is changing tissue engineering by offering pathways to otherwise unattainable, highly complex scaffold morphologies.