Structure-Processing-Property Relationships of 3D Printed Porous Polymeric Materials

Mechanically Strengthened Aerogels through Multiscale, Multicompositional, and Multidimensional Approaches: A Review

In recent decades, aerogels have attracted tremendous attention in academia and industry as a class of lightweight and porous multifunctional nanomaterial. Despite their wide application range, the low mechanical durability hinders their processing and handling, particularly in applications requiring complex physical structures. "Mechanically strengthened aerogels" have emerged as a potential solution to address this drawback. Since the first report on aerogels in 1931, various modified synthesis processes have been introduced in the last few decades to enhance the aerogel mechanical strength, further advancing their multifunctional scope. This review summarizes the state-of-the-art developments of mechanically strengthened aerogels through multicompositional and multidimensional approaches. Furthermore, new trends and future directions for as prevailed commercialization of aerogels as plastic materials are discussed.

Porous Polymer Structures with Tunable Mechanical Properties Using a Water Emulsion Ink

Recently, the manufacturing of porous polydimethylsiloxane (PDMS) with engineered porosity has gained considerable interest due to its tunable material properties and diverse applications. An innovative approach to control the porosity of PDMS is to use transient liquid phase water to improve its mechanical properties, which has been explored in this work. Adjusting the ratios of deionized water to the PDMS precursor during blending and subsequent curing processes allows for controlled porosity, yielding water emulsion foam with tailored properties. The PDMS-to-water weight ratios were engineered ranging from 100:0 to 10:90, with the 65:35 specimen exhibiting the best mechanical properties with a Young's Modulus of 1.17 MPa, energy absorption of 0.33 MPa, and compressive strength of 3.50 MPa. This led to a porous sample exhibiting a 31.46% increase in the modulus of elasticity over a bulk PDMS sample. Dowsil SE 1700 was then added, improving the storage capabilities of the precursor. The optimal storage temperature was probed, with -60 °C resulting in great pore stability throughout a three-week duration. The possibility of using these water emulsion foams for paste extrusion additive manufacturing (AM) was also analyzed by implementing a rheological modifier, fumed silica. Fumed silica's impact on viscosity was examined, revealing that 9 wt% of silica demonstrates optimal rheological behaviors for AM, bearing a viscosity of 10,290 Pa·s while demonstrating shear-thinning and thixotropic behavior. This study suggests that water can be used as pore-formers for PDMS in conjunction with AM to produce engineered materials and structures for aerospace, medical, and defense industries as sensors, microfluidic devices, and lightweight structures.

Enabling New Approaches: Recent Advances in Processing Aliphatic Polycarbonate-Based Materials

Aliphatic polycarbonates (aPCs) have become increasingly popular as functional materials due to their biocompatibility and capacity for on-demand degradation. Advances in polymerization techniques and the introduction of new functional monomers have expanded the library of aPCs available, offering a diverse range of chemical compositions and structures. To accommodate the emerging requirements of new applications in biomedical and energy-related fields, various manufacturing techniques have been adopted for processing aPC-based materials. However, a summary of these techniques has yet to be conducted. The aim of this paper is to enrich the toolbox available to researchers, enabling them to select the most suitable technique for their materials. In this paper, a concise review of the recent progress in processing techniques, including controlled self-assembly, electrospinning, additive manufacturing, and other techniques, is presented. We also highlight the specific challenges and opportunities for the sustainable growth of this research area and the successful integration of aPCs in industrial applications.

Printing Composites with Salt Hydrate Phase Change Materials for Thermal Energy Storage

Salt hydrate phase change materials are important in advancing thermal energy storage technologies for the development of renewable energies. At present, their widespread use is limited by undesired undercooling and phase separation, as well as their tendency to corrode container materials. Herein, we report a direct ink writing (DIW) additive manufacturing technique to print noncorrosive salt hydrate composites with thoroughly integrated nucleating agents and thermally conductive additives. First, salt hydrate particles are prepared from nonaqueous Pickering emulsions and then employed as rheological modifiers to formulate thixotropic inks with polymer dispersions in toluene serving as the matrix. These inks are successfully printed at room temperature and cured by solvent evaporation under ambient conditions. The resulting printed and cured composites, containing up to 70 wt % of the salt hydrate, exhibit reliable thermal cyclability for 10 cycles and suppressed undercooling compared to the bulk salt hydrate. Remarkably, the composites consistently maintain their structural integrity and thermal performance throughout the entirety of both the melting and solidification processes. We demonstrate the versatility of this approach by utilizing two salt hydrates, magnesium nitrate hexahydrate (MNH, Tm = 89 °C) and zinc nitrate hexahydrate (ZNH, Tm = 36 °C), to achieve desired thermal characteristics across a wide range of temperatures. Further, we establish that the incorporation of carbon black in these inks enhances the thermal conductivity by at least 33%. This approach consolidates the strengths of additive manufacturing and salt hydrate phase change materials to harness customizable thermal properties, well suited for targeted thermal energy management applications.

Low Impact Velocity Modeling of 3D Printed Spatially Graded Elastomeric Lattices

Additive manufacturing technologies have facilitated the construction of intricate geometries, which otherwise would be an extenuating task to accomplish by using traditional processes. Particularly, this work addresses the manufacturing, testing, and modeling of thermoplastic polyurethane (TPU) lattices. Here, a discussion of different unit cells found in the literature is presented, along with the based materials used by other authors and the tests performed in diverse studies, from which a necessity to improve the dynamic modeling of polymeric lattices was identified. This research focused on the experimental and numerical analysis of elastomeric lattices under quasi-static and dynamic compressive loads, using a Kelvin unit cell to design and build non-graded and spatially side-graded lattices. The base material behavior was fitted to an Ogden 3rd-order hyperelastic material model and used as input for the numerical work through finite element analysis (FEA). The quasi-static and impact loading FEA results from the lattices showed a good agreement with the experimental data, and by using the validated simulation methodology, additional special cases were simulated and compared. Finally, the information extracted from FEA allowed for a comparison of the performance of the lattice configurations considered herein.

Emerging porous organic polymers for biomedical applications

This review summarizes and discusses the recent progress in porous organic polymers for diverse biomedical applications such as drug delivery, biomacromolecule immobilization, phototherapy, biosensing, bioimaging, and antibacterial applications.

Scalable 3D-printed lattices for pressure control in fluid applications

Additive manufacturing affords precise control over geometries with high degrees of complexity and pre-defined structure. Lattices are one class of additive-only structures which have great potential in directing transport phenomena because they are highly ordered, scalable, and modular. However, a comprehensive description of how these structures scale and interact in heterogeneous systems is still undetermined. To advance this aim, we designed cubic and Kelvin lattices at two sub-5 mm length scales and compared published correlations to the experimental pressure gradient in pipes ranging from 12-52 mm diameter. We further investigated all combinations of the four lattices to evaluate segmented combinatorial behavior. The results suggest that a single correlation can describe pressure behavior for different lattice geometries and scales. Furthermore, combining lattice systems in series has a complex effect that is sensitive to part geometry. Together, these developments support the promise for tailored, modular lattice systems at laboratory scales and beyond.