Scalable Alignment and Selective Deposition of Nanoparticles for Multifunctional Sensor Applications

3D-Printed Polymeric Biomaterials for Health Applications

3D printing, also known as additive manufacturing, holds immense potential for rapid prototyping and customized production of functional health-related devices. With advancements in polymer chemistry and biomedical engineering, polymeric biomaterials have become integral to 3D-printed biomedical applications. However, there still exists a bottleneck in the compatibility of polymeric biomaterials with different 3D printing methods, as well as intrinsic challenges such as limited printing resolution and rates. Therefore, this review aims to introduce the current state-of-the-art in 3D-printed functional polymeric health-related devices. It begins with an overview of the landscape of 3D printing techniques, followed by an examination of commonly used polymeric biomaterials. Subsequently, examples of 3D-printed biomedical devices are provided and classified into categories such as biosensors, bioactuators, soft robotics, energy storage systems, self-powered devices, and data science in bioplotting. The emphasis is on exploring the current capabilities of 3D printing in manufacturing polymeric biomaterials into desired geometries that facilitate device functionality and studying the reasons for material choice. Finally, an outlook with challenges and possible improvements in the near future is presented, projecting the contribution of general 3D printing and polymeric biomaterials in the field of healthcare.

3D Printing-Induced Hierarchically Aligned Nanocomposites With Exceptional Multidirectional Strain Sensing Performance

High-performance sensors capable of detecting multidirectional strains are indispensable to understand the complex motions involved in flexible electronics. Conventional isotropic strain sensors can only measure uniaxial deformations or single stimuli, hindering their practical application fields. The answer to such challenge resides in the construction of engineered anisotropic sensing structures. Herein, a hierarchically aligned carbon nanofiber (CNF)/polydimethylsiloxane nanocomposite strain sensor is developed by one-step 3D printing. The precisely controlled printing path and shear flow bring about highly aligned nanocomposite filaments at macroscale and orientated CNF network within each filament at microscale. The periodically orientated nanocomposite filaments along with the inner aligned CNF network successfully control the strain distribution and the appearance of microcracks, giving rise to anisotropic structural response to external deformations. The synergetic effect of the multiscale structural design leads to distinguishable gauge factors of 164 and 0.5 for applied loadings along and transverse to the alignment direction, leading to an exceptional selectivity of 3.77. The real-world applications of the hierarchically aligned sensors in multiaxial movement detector and posture-correction device are further demonstrated. The above findings propose new ideas for manufacturing nanocomposites with engineered anisotropic structure and properties, verifying promising applications in emerging wearable electronics and soft robotics.

Rapid fabrication of gold microsphere arrays with stable deep-pressing anisotropic conductivity for advanced packaging

Smooth metal microspheres with uniform sizes are ideal for constructing particle-arrayed anisotropic conductive films (ACF), but synthesis is hindered by challenges in controlling anisotropic metal growth. Here, we present a positioned transient-emulsion self-assembly and laser-irradiation strategy to fabricate pure gold microsphere arrays with smooth surfaces and uniform sizes. The fabrication involves assembling gold nanoparticles into uniform colloidosomes within a pre-designed microhole array, followed by rapid transformation into well-defined microspheres through laser heating. The gold nanoparticles melt and merge in a layer-by-layer manner due to the finite skin depth of the laser, leading to a localized photothermal effect. This strategy circumvents anisotropic growth, enables tunable control of microsphere size and positioning, and is compatible with conventional lithography. Importantly, these pure gold microspheres exhibit stable conductivity under deep compression, offering promising applications in soldering micro-sized chips onto integrated circuits.

Using Decellularized Magnetic Microrobots to Deliver Functional Cells for Cartilage Regeneration

The use of natural cartilage extracellular matrix (ECM) has gained widespread attention in the field of cartilage tissue engineering. However, current approaches for delivering functional scaffolds for osteoarthritis (OA) therapy rely on knee surgery, which is limited by the narrow and complex structure of the articular cavity and carries the risk of injuring surrounding tissues. This work introduces a novel cell microcarrier, magnetized cartilage ECM-derived scaffolds (M-CEDSs), which are derived from decellularized natural porcine cartilage ECM. Human bone marrow mesenchymal stem cells are selected for their therapeutic potential in OA treatments. Owing to their natural composition, M-CEDSs have a biomechanical environment similar to that of human cartilage and can efficiently load functional cells while maintaining high mobility. The cells are released spontaneously at a target location for at least 20 days. Furthermore, cell-seeded M-CEDSs show better knee joint function recovery than control groups 3 weeks after surgery in preclinical experiments, and ex vivo experiments reveal that M-CEDSs can rapidly aggregate inside tissue samples. This work demonstrates the use of decellularized microrobots for cell delivery and their in vivo therapeutic effects in preclinical tests.

Nanoparticle Assembly: From Self-Organization to Controlled Micropatterning for Enhanced Functionalities

Nanoparticles form long-range micropatterns via self-assembly or directed self-assembly with superior mechanical, electrical, optical, magnetic, chemical, and other functional properties for broad applications, such as structural supports, thermal exchangers, optoelectronics, microelectronics, and robotics. The precisely defined particle assembly at the nanoscale with simultaneously scalable patterning at the microscale is indispensable for enabling functionality and improving the performance of devices. This article provides a comprehensive review of nanoparticle assembly formed primarily via the balance of forces at the nanoscale (e.g., van der Waals, colloidal, capillary, convection, and chemical forces) and nanoparticle-template interactions (e.g., physical confinement, chemical functionalization, additive layer-upon-layer). The review commences with a general overview of nanoparticle self-assembly, with the state-of-the-art literature review and motivation. It subsequently reviews the recent progress in nanoparticle assembly without the presence of surface templates. Manufacturing techniques for surface template fabrication and their influence on nanoparticle assembly efficiency and effectiveness are then explored. The primary focus is the spatial organization and orientational preference of nanoparticles on non-templated and pre-templated surfaces in a controlled manner. Moreover, the article discusses broad applications of micropatterned surfaces, encompassing various fields. Finally, the review concludes with a summary of manufacturing methods, their limitations, and future trends in nanoparticle assembly.

Outstanding Synergy of Sensitivity and Linear Range Enabled by Multigradient Architectures

Flexible pressure sensors are devices that mimic the sensory capabilities of natural human skin and enable robots to perceive external stimuli. One of the main challenges is maintaining high sensitivity over a broad linear pressure range due to poor structural compressibility. Here, we report a flexible pressure sensor with an ultrahigh sensitivity of 153.3 kPa-1 and linear response over an unprecedentedly broad pressure range from 0.0005 to 1300 kPa based on interdigital-shaped, multigradient architectures, featuring modulus, conductivity, and microstructure gradients. Such multigradient architectures and interdigital-shaped configurations enable effective stress transfer and conductivity regulation, evading the pressure sensitivity-linear range trade-off dilemma. Together with high pressure resolution, high frequency response, and good reproducibility over the ultrabroad linear range, proof-of-concept applications such as acoustic wave detection, high-resolution pressure measurement, and healthcare monitoring in diverse scenarios are demonstrated.

Deposition and alignment of fiber suspensions by dip coating

HYPOTHESIS

The dip coating of suspensions made of monodisperse non-Brownian spherical particles dispersed in a Newtonian fluid leads to different coating regimes depending on the ratio of the particle diameter to the thickness of the film entrained on the substrate. In particular, dilute particles dispersed in the liquid are entrained only above a threshold value of film thickness. In the case of anisotropic particles, in particular fibers, the smallest characteristic dimension will control the entrainment of the particle. Furthermore, it is possible to control the orientation of the anisotropic particles depending on the substrate geometry. In the thick film regime, the Landau-Levich-Derjaguin model remains valid if one account for the change in viscosity.

EXPERIMENT

To test the hypotheses, we performed dip-coating experiments with dilute suspensions of non-Brownian fibers with different length-to-diameter aspect ratios. We characterize the number of fibers entrained on the surface of the substrate as a function of the withdrawal velocity, allowing us to estimate a threshold capillary number below which all the particles remain in the liquid bath. Besides, we measure the angular distribution of the entrained fibers for two different substrate geometries: flat plates and cylindrical rods. We then measure the film thickness for more concentrated fiber suspensions.

FINDINGS

The entrainment of the fibers on a flat plate and a cylindrical rod is primarily controlled by the smaller characteristic length of the fibers: their diameter. At first order, the entrainment threshold scales similarly to that of spherical particles. The length of the fibers only appears to have a minor influence on the entrainment threshold. No preferential alignment is observed for non-Brownian fibers on a flat plate, except for very thin films, whereas the fibers tend to align themselves along the axis of a cylindrical rod for a large enough ratio of the fiber length to the radius of the cylindrical rod. The Landau-Levich-Derjaguin law is recovered for more concentrated suspension by introducing an effective capillary number accounting for the change in viscosity.

Advancements in Nanoparticle Deposition Techniques for Diverse Substrates: A Review

Nanoparticle deposition on various substrates has gained significant attention due to the potential applications of nanoparticles in various fields. This review paper comprehensively analyzes different nanoparticle deposition techniques on ceramic, polymeric, and metallic substrates. The deposition techniques covered include electron gun evaporation, physical vapor deposition, plasma enriched chemical vapor deposition (PECVD), electrochemical deposition, chemical vapor deposition, electrophoretic deposition, laser metal deposition, and atomic layer deposition (ALD), thermophoretic deposition, supercritical deposition, spin coating, and dip coating. Additionally, the sustainability aspects of these deposition techniques are discussed, along with their potential applications in anti-icing, antibacterial power, and filtration systems. Finally, the review explores the importance of deposition purities in achieving optimal nanomaterial performance. This comprehensive review aims to provide valuable insights into state-of-the-art techniques and applications in the field of nanomaterial deposition.

Defect-Induced Adsorption Switching (p- to n- Type) in Conducting Bare Carbon Nanotube Film for the Development of Highly Sensitive and Flexible Chemiresistive-Based Methanol and NO2 Sensor

Lightweight and flexible gas sensors are essentially required for the fast detection of toxic gases to pass on the early warning to deter accident situations caused by gas leakage. In view of this, we have fabricated a thin paper-like free-standing, flexible, and sensitive carbon nanotube (CNT) aerogel gas sensor. The CNT aerogel film synthesized by the floating catalyst chemical vapor deposition method consists of a tiny network of long CNTs and ∼20% amorphous carbon. The pores and defect density of the CNT aerogel film were tuned by heating at 700 °C to obtain a sensor film, which showed excellent sensitivity for toxic NO₂ and methanol gas in the concentration range of 1-100 ppm with a remarkable limit of detection ∼90 ppb. This sensor has consistently responded to toxic gas even after bending and crumpling the film. Moreover, the film heat-treated at 900 °C showed a lower response with opposite sensing characteristics due to switching of the semiconductor nature of the CNT aerogel film to n-type from p-type. The annealing temperature-based adsorption switching can be related to a type of carbon defect in the CNT aerogel film. Therefore, the developed free-standing, highly sensitive, and flexible CNT aerogel sensor paves the way for a reliable, robust, and switchable toxic gas sensor.

Dual-function photonic spin Hall effect sensor for high-precision refractive index sensing and graphene layer detection

In this paper, a photonic spin Hall effect (PSHE) sensor for high-precision refractive index (RI) detection and graphene layer number detection is proposed. Numerical analysis is performed by the transfer matrix method. The graphene material is introduced into the layered topology to stimulate the generation of PSHE phenomenon, and both H polarization and V polarization displacements occur simultaneously. The effects of parameters such as chemical potential, relaxation time, and external temperature on the PSHE shift are also discussed. The displacement of H polarization can be used for RI detection, and the measurement range (MR), sensitivity (S), figure of merit (FOM), and detection limit (DL) are 1.1-1.5, 127.85 degrees/RIU, 2412, and 2.08×10^-5, respectively. The superior sensing performance provides a theoretical possibility for the detection of solids, liquids, and gases. The shift characteristic of V polarization is appropriate for detecting the number of layers in graphene, with a MR and S of 1-9 layers and 4.54 degrees/layer. The impacts of dielectric loss on sensor performance are also considered. We hope that the proposed PSHE multifunctional sensor can improve a theoretical idea for novel sensor design.

Magnetic Nanoparticles: Current Advances in Nanomedicine, Drug Delivery and MRI

Magnetic nanoparticles (MNPs) have evolved tremendously during recent years, in part due to the rapid expansion of nanotechnology and to their active magnetic core with a high surface-to-volume ratio, while their surface functionalization opened the door to a plethora of drug, gene and bioactive molecule immobilization. Taming the high reactivity of the magnetic core was achieved by various functionalization techniques, producing MNPs tailored for the diagnosis and treatment of cardiovascular or neurological disease, tumors and cancer. Superparamagnetic iron oxide nanoparticles (SPIONs) are established at the core of drug-delivery systems and could act as efficient agents for MFH (magnetic fluid hyperthermia). Depending on the functionalization molecule and intrinsic morphological features, MNPs now cover a broad scope which the current review aims to overview. Considering the exponential expansion of the field, the current review will be limited to roughly the past three years.

3D Printing-Enabled Nanoparticle Alignment: A Review of Mechanisms and Applications

3D printing (additive manufacturing (AM)) has enormous potential for rapid tooling and mass production due to its design flexibility and significant reduction of the timeline from design to manufacturing. The current state-of-the-art in 3D printing focuses on material manufacturability and engineering applications. However, there still exists the bottleneck of low printing resolution and processing rates, especially when nanomaterials need tailorable orders at different scales. An interesting phenomenon is the preferential alignment of nanoparticles that enhance material properties. Therefore, this review emphasizes the landscape of nanoparticle alignment in the context of 3D printing. Herein, a brief overview of 3D printing is provided, followed by a comprehensive summary of the 3D printing-enabled nanoparticle alignment in well-established and in-house customized 3D printing mechanisms that can lead to selective deposition and preferential orientation of nanoparticles. Subsequently, it is listed that typical applications that utilized the properties of ordered nanoparticles (e.g., structural composites, heat conductors, chemo-resistive sensors, engineered surfaces, tissue scaffolds, and actuators based on structural and functional property improvement). This review's emphasis is on the particle alignment methodology and the performance of composites incorporating aligned nanoparticles. In the end, significant limitations of current 3D printing techniques are identified together with future perspectives.