High-resolution, high-aspect ratio conductive wires embedded in plastic substrates

Factors Affecting Orthopedic Sports Medicine Surgeons' Online Reputation

Physician rating websites (PRWs) rate physicians based on experiences of previous patients. Although a high rating is desirable, it may not correlate with quality of care, experience, or other physician-specific variables. This study examined the impact of physician-specific variables, such as American Board of Orthopaedic Surgery Sports Certificate of Added Qualification (CAQ) status, years in practice, sex, and geographic location, on the PRW patient satisfaction rating and number of ratings. A list of orthopedic sports medicine surgeons was obtained from the American Orthopaedic Society for Sports Medicine database. Demographic data were recorded. Surgeon profiles were gathered from the most commonly used PRWs (Healthgrades and Vitals), and a mean rating value was recorded on a 1- to 5-star scale. The t test and analysis of variance were used for comparisons. Multivariable linear regression was used to identify factors contributing to PRW ratings. Female sex had the biggest positive effect on PRW rating (R=0.04, P=.029). The PRW rating was positively affected by the number of ratings (R=0.04, P<.001) and negatively affected by an increase in years of practice (R=0.04, P<.001). Surgeons with fewer than 10 years in practice had higher PRW ratings than surgeons practicing longer than 10 years. The PRW ratings were not affected by sports CAQ status or geographic location. Fewer years in practice, female sex, and greater number of reviews were associated with higher PRW ratings. Number of reviews was the only modifiable factor. There was no observed association between sports medicine CAQ status and PRW rating. [Orthopedics. 2021;44(2):e281-e286.].

Templateless, Plating-Free Fabrication of Flexible Transparent Electrodes with Embedded Silver Mesh by Electric-Field-Driven Microscale 3D Printing and Hybrid Hot Embossing

Flexible transparent electrodes (FTEs) with an embedded metal mesh are considered a promising alternative to traditional indium tin oxide (ITO) due to their excellent photoelectric performance, surface roughness, and mechanical and environmental stability. However, great challenges remain for achieving simple, cost-effective, and environmentally friendly manufacturing of high-performance FTEs with embedded metal mesh. Herein, a maskless, templateless, and plating-free fabrication technique is proposed for FTEs with embedded silver mesh by combining an electric-field-driven (EFD) microscale 3D printing technique and a newly developed hybrid hot-embossing process. The final fabricated FTE exhibits superior optoelectronic properties with a transmittance of 85.79%, a sheet resistance of 0.75 Ω sq^-1 , a smooth surface of silver mesh (R_a  ≈ 18.8 nm) without any polishing treatment, and remarkable mechanical stability and environmental adaptability with a negligible increase in sheet resistance under diverse cyclic tests and harsh working conditions (1000 bending cycles, 80 adhesion tests, 120 scratch tests, 100 min ultrasonic test, and 72 h chemical attack). The practical viability of this FTE is successfully demonstrated with a flexible transparent heater applied to deicing. The technique proposed offers a promising fabrication strategy with a cost-effective and environmentally friendly process for high-performance FTE.

Compatible Ag+ Complex-Assisted Ultrafine Copper Pattern Deposition on Poly(ethylene terephtalate) Film with Micro Inkjet Printing

Firm immobilization of catalysts on the predesigned position over substrates is an essential process for producing flexible circuits by the electroless deposition (ELD) process. In this work, a compatible Ag⁺ complex was developed and directly printed on the poly(ethylene terephtalate) (PET) film through a micro inkjet printing instrument to trigger the deposition of ultrafine copper patterns with approximately 20 μm in width. Morphological and elementary characterization verified that the nanosized silver catalyst was uniformly distributed in the bridge layer, which could enhance the adhesion between the PET film and deposited copper patterns. Moreover, after 30 min of ELD, the copper patterns exhibited a low resistivity of 2.68 × 10^-6 Ω·cm and maintained considerable conductivity even after 2000 times of cyclical bending. These interesting conductive and mechanical features demonstrate the tremendous potential of this Ag⁺ complex-assisted copper deposition in the interconnection of high-density integrated flexible electronics.

3D-Printed Hydrogel Composites for Predictive Temporal (4D) Cellular Organizations and Patterned Biogenic Mineralization

Materials chemistries for hydrogel scaffolds that are capable of programming temporal (4D) attributes of cellular decision-making in supported 3D microcultures are described. The scaffolds are fabricated using direct-ink writing (DIW)-a 3D-printing technique using extrusion to pattern scaffolds at biologically relevant diameters (≤ 100 µm). Herein, DIW is exploited to variously incorporate a rheological nanoclay, Laponite XLG (LAP), into 2-hydroxyethyl methacrylate (HEMA)-based hydrogels-printing the LAP-HEMA (LH) composites as functional modifiers within otherwise unmodified 2D and 3D HEMA microstructures. The nanoclay-modified domains, when tested as thin films, require no activating (e.g., protein) treatments to promote robust growth compliances that direct the spatial attachment of fibroblast (3T3) and preosteoblast (E1) cells, fostering for the latter a capacity to direct long-term osteodifferentiation. Cell-to-gel interfacial morphologies and cellular motility are analyzed with spatial light interference microscopy (SLIM). Through combination of HEMA and LH gels, high-resolution DIW of a nanocomposite ink (UniH) that translates organizationally dynamic attributes seen with 2D gels into dentition-mimetic 3D scaffolds is demonstrated. These analyses confirm that the underlying materials chemistry and geometry of hydrogel nanocomposites are capable of directing cellular attachment and temporal development within 3D microcultures-a useful material system for the 4D patterning of hydrogel scaffolds.

Capillary force induced air film for self-aligned short channel: pushing the limits of inkjet printing

Ultrashort channels of electrodes are essential for the construction of advanced functional devices with high-level integration and high operation speed. However, the channel length of fabricated electrodes is limited to 20 μm in inkjet printing. Although several methods have been previously proposed to obtain short channels, they require extra processing steps. In this paper, channel self-aligning phenomenon was observed in directly patterned electrodes on unmodified substrate by inkjet printing, when using an interspace defects growing method. Further exploring the underlying mechanism reveals that the capillary force induced air film prevents droplets coalescence, even on a substrate with no temperature differences. The wetting region, which is generated by the receding droplets impingement, will draw droplets closer together at a larger drop space, thus demanding smaller air pressure for coalescence inhibition and contributing to the self-aligning phenomenon of micro-sized droplets released by inkjet printing. Accordingly, an ultrashort channel of 2.38 μm is obtained with relatively smooth boundaries, when electrodes are printed on a slightly heated substrate, which reduces the air pressure between two neighboring droplets. This work will provide a significant reference for future high resolution applications of inkjet printing technology.

Critical Impact of Solvent Evaporation on the Resolution of Inkjet Printed Nanoparticles Film

We first verify the critical role of solvent evaporation on the resolution of inkjet printing. To confirm our hypothesis, we adjusted the evaporation rate gradient along the surface of adjacent droplets by controlling the drying microenvironment. Uneven solvent evaporation flux caused thermocapillary surface flow inward the space of micrometer-sized droplets and increase the air pressure, which prevented the neighboring droplets from coalescence. When reducing the droplet distance by the solvent evaporation-based method, a uniform profile could be obtained at the same time. This work brings us a step closer to resolving one of the critical bottlenecks to commercializing printed electronic goods.

Capillary Coatings: Flow and Drying Dynamics in Open Microchannels

Capillary flow and drying of polymer solutions in open microchannels are explored over time scales spanning seven orders of magnitude: from capillary filling (10^-3-10 s) to the formation of a dry thin film (a "capillary coating"; 10²-10³ s). During capillary filling, drying-induced changes (increased solids content and viscosity) generate microscale pinning events that impede contact line motion. Three unique types of pinning are identified and characterized, each defined by the specific location(s) along the contact line at which pinning is induced. Drying is shown to ultimately pin the contact line permanently, and the associated total flow distances and times are revealed to be strong functions of channel width and drying rate. In general, lower drying rates coupled with intermediate channel widths are found to be most conducive to longer flow distances and times. After the advancing contact line permanently pins, internal flows driven by uneven evaporation rates continue to drive polymer to the contact line. This phenomenon promotes a local accumulation of solids and persists until all motion is arrested by drying. The effects of channel width and drying rate are investigated at each stage of this capillary coating process. These results are then applied to case studies of two functional inks commonly used in printed electronics fabrication: a PEDOT:PSS (poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate)) ink and a graphene ink. Although drying is shown to permanently arrest flow in both inks, both systems exhibit an increased resistance to pinning unexplained by mechanisms identified in aqueous polymer systems. Instead, arguments based on chemistry, particle size, and rheology are used to explain their novel behavior. These case studies provide insight into how functional inks can be better designed to optimize flow distances and maximize overall dry film uniformity in capillary coatings.

All-Printed, Self-Aligned Carbon Nanotube Thin-Film Transistors on Imprinted Plastic Substrates

We present a self-aligned process for printing thin-film transistors (TFTs) on plastic with single-walled carbon nanotube (SWCNT) networks as the channel material. The SCALE (self-aligned capillarity-assisted lithography for electronics) process combines imprint lithography with inkjet printing. Specifically, inks are jetted into imprinted reservoirs, where they then flow into narrow device cavities due to capillarity. Here, we incorporate a composite high- k gate dielectric and an aligned conducting polymer gate electrode in the SCALE process to enable a smaller areal footprint than prior designs that yields low-voltage SWCNT TFTs with average p-type carrier mobilities of 4 cm²/V·s and ON/OFF current ratios of 10⁴. Our work demonstrates the promising potential of the SCALE process to fabricate SWCNT-based TFTs with favorable I- V characteristics on plastic substrates.

Chemical formation of soft metal electrodes for flexible and wearable electronics

Efficient chemical approaches to fabricating soft metal electrodes aiming at wearable electronics are summarized and reviewed.

Modulus- and Surface-Energy-Tunable Thiol-ene for UV Micromolding of Coatings

Micromolding of UV-curable materials is a patterning method to fabricate microstructured surfaces that is an additive manufacturing process fully compatible with roll-to-roll systems. The development of micromolding for mass production remains a challenge because of the multifaceted demands of UV curable materials and the risk of demolding-related defects, particularly when patterning high-aspect-ratio features. In this research, a robust micromolding approach is demonstrated that integrates thiol-ene polymerization and UV LED curing. The moduli of cured thiol-ene coatings were tuned over 2 orders of magnitude by simply adjusting the acrylate concentration of a coating formulation, the curing completed in all cases within 10 s of LED exposure. Densely packed 50-μm-wide gratings were faithfully replicated in coatings ranging from soft materials to stiff highly cross-linked networks. Further, surface energy was modified with a fluorinated polymer, achieving a surface energy reduction of more than a half at a loading of 1 wt %, and enabling tall (100 μm) defect-free patterns to be attained. The demolding strengths of microstructured coatings were compared using quantitative peel testing, showing its decrease with decreasing surface energy, coating modulus, and grating height. This micromolding process, combining tunability in thermomechanical and surface properties, makes thiol-ene microstructured coatings attractive candidates for roll-to-roll manufacture. As a demonstration of the utility of the process, superhydrophobic surfaces are prepared using the system modified by the fluorinated polymer.

Dynamics of Capillary-Driven Flow in 3D Printed Open Microchannels

Microchannels have applications in microfluidic devices, patterns for micromolding, and even flexible electronic devices. Three-dimensional (3D) printing presents a promising alternative manufacturing route for these microchannels due to the technology's relative speed and the design freedom it affords its users. However, the roughness of 3D printed surfaces can significantly influence flow dynamics inside of a microchannel. In this work, open microchannels are fabricated using four different 3D printing techniques: fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering, and multi jet modeling. Microchannels printed with each technology are evaluated with respect to their surface roughness, morphology, and how conducive they are to spontaneous capillary filling. Based on this initial assessment, microchannels printed with FDM and SLA are chosen as models to study spontaneous, capillary-driven flow dynamics in 3D printed microchannels. Flow dynamics are investigated over short (∼10^-3 s), intermediate (∼1 s), and long (∼10² s) time scales. Surface roughness causes a start-stop motion down the channel due to contact line pinning, while the cross-sectional shape imparted onto the channels during the printing process is shown to reduce the expected filling velocity. A significant delay in the onset of Lucas-Washburn dynamics (a long-time equilibrium state where meniscus position advances proportionally to the square root of time) is also observed. Flow dynamics are assessed as a function of printing technology, print orientation, channel dimensions, and liquid properties. This study provides the first in-depth investigation of the effect of 3D printing on microchannel flow dynamics as well as a set of rules on how to account for these effects in practice. The extension of these effects to closed microchannels and microchannels fabricated with other 3D printing technologies is also discussed.

A low-cost, highly-conductive polyvinyl alcohol flexible film with Ag-microsheets and AgNWs as fillers

Low-cost, high-conductivity flexible conductive films were fabricated using Ag-microsheets, Ag-nanowires (AgNWs) and polyvinyl alcohol (PVA) as conducting agents. The flexible conductive film shows good conductivity under stretching.

One-Step Preparation of Silver Hexagonal Microsheets as Electrically Conductive Adhesive Fillers for Printed Electronics

A facile one-step solution-phase chemical reduction method has been developed to synthesize Ag microsheets at room temperature. The morphology of Ag sheets is a regular hexagon more than 1 μm in size and about 200 nm in thickness. The hexagonal Ag microsheets possess a smoother and straighter surface compared with that of the commercial Ag micrometer-sized flakes prepared by ball milling for electrically conductive adhesives (ECAs). The function of the reagents and the formation mechanism of Ag hexagonal microsheets are also investigated. For the polyvinylpyrrolidone (PVP) and citrate facet-selective capping, the Ag atoms freshly reduced by N2H4 would orientationally grow alone on the {111} facet of Ag seeds, with the synergistically selective etching of irregular and small Ag particles by H2O2, to form Ag hexagonal microsheets. The hexagonal Ag microsheet-filled epoxy adhesives, as electrically conductive materials, can be easily printed on various substrates such as polyethylene terephthalate (PET), epoxy, glass, and flexible papers. The hexagonal Ag microsheet filled ECAs demonstrate lower bulk resistivity (approximately 8 × 10(-5) Ω cm) than that of the traditional Ag micrometer-sized-flake-filled ECAs with the same Ag content of 80 wt % (approximately 1.2 × 10(-4) Ω cm).