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Xu Y, Tang L, Nok-iangthong C, Wagner M, Baumann G, Feist F, Bismarck A, Jiang Q. Functionally Gradient Macroporous Polymers: Emulsion Templating Offers Control over Density, Pore Morphology, and Composition. ACS APPLIED POLYMER MATERIALS 2024; 6:5150-5162. [PMID: 38752018 PMCID: PMC11091853 DOI: 10.1021/acsapm.4c00261] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/24/2024] [Revised: 04/09/2024] [Accepted: 04/09/2024] [Indexed: 05/18/2024]
Abstract
Gradient macroporous polymers were produced by polymerization of emulsion templates comprising a continuous monomer phase and an internal aqueous template phase. To produce macroporous polymers with gradient composition, pore size, and foam density, we varied the template formulation, droplet size, and internal phase ratio of emulsion templates continuously and stacked those prior to polymerization. Using the outlined approach, it is possible to vary one property along the resulting macroporous polymer while retaining the other properties. The elastic moduli and crush strengths change along the gradient of the macroporous polymers; their mechanical properties are dominated by those of the weakest layers in the gradient. Macroporous polymers with gradient chemical composition and thus stiffness provide both high impact load and energy adsorption, rendering the gradient foam suitable for impact protective applications. We show that dual-dispensing and simultaneous blending of two different emulsion formulations in various ratios results in a fine, bidirectional change of the template composition, enabling the production of true gradient macroporous polymers with a high degree of design freedom.
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Affiliation(s)
- Yufeng Xu
- Institute
of Material Chemistry and Research, Faculty of Chemistry, University of Vienna, Währinger Strasse 42, 1090 Vienna, Austria
| | - Le Tang
- Institute
of Material Chemistry and Research, Faculty of Chemistry, University of Vienna, Währinger Strasse 42, 1090 Vienna, Austria
| | - Chanokporn Nok-iangthong
- Institute
of Material Chemistry and Research, Faculty of Chemistry, University of Vienna, Währinger Strasse 42, 1090 Vienna, Austria
| | - Markus Wagner
- Institute
for Vehicle Safety, Graz University of Technology, Inffeldgasse 13 VI, 8010 Graz, Austria
| | - Georg Baumann
- Institute
for Vehicle Safety, Graz University of Technology, Inffeldgasse 13 VI, 8010 Graz, Austria
| | - Florian Feist
- Institute
for Vehicle Safety, Graz University of Technology, Inffeldgasse 13 VI, 8010 Graz, Austria
| | - Alexander Bismarck
- Institute
of Material Chemistry and Research, Faculty of Chemistry, University of Vienna, Währinger Strasse 42, 1090 Vienna, Austria
- Department
of Chemical Engineering, Imperial College
London, South Kensington
Campus, London SW7 2AZ, U.K.
| | - Qixiang Jiang
- Institute
of Material Chemistry and Research, Faculty of Chemistry, University of Vienna, Währinger Strasse 42, 1090 Vienna, Austria
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2
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Duarte LC, Figueredo F, Chagas CLS, Cortón E, Coltro WKT. A review of the recent achievements and future trends on 3D printed microfluidic devices for bioanalytical applications. Anal Chim Acta 2024; 1299:342429. [PMID: 38499426 DOI: 10.1016/j.aca.2024.342429] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/16/2023] [Revised: 02/25/2024] [Accepted: 02/26/2024] [Indexed: 03/20/2024]
Abstract
3D printing has revolutionized the manufacturing process of microanalytical devices by enabling the automated production of customized objects. This technology promises to become a fundamental tool, accelerating investigations in critical areas of health, food, and environmental sciences. This microfabrication technology can be easily disseminated among users to produce further and provide analytical data to an interconnected network towards the Internet of Things, as 3D printers enable automated, reproducible, low-cost, and easy fabrication of microanalytical devices in a single step. New functional materials are being investigated for one-step fabrication of highly complex 3D printed parts using photocurable resins. However, they are not yet widely used to fabricate microfluidic devices. This is likely the critical step towards easy and automated fabrication of sophisticated, complex, and functional 3D-printed microchips. Accordingly, this review covers recent advances in the development of 3D-printed microfluidic devices for point-of-care (POC) or bioanalytical applications such as nucleic acid amplification assays, immunoassays, cell and biomarker analysis and organs-on-a-chip. Finally, we discuss the future implications of this technology and highlight the challenges in researching and developing appropriate materials and manufacturing techniques to enable the production of 3D-printed microfluidic analytical devices in a single step.
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Affiliation(s)
- Lucas C Duarte
- Instituto de Química, Universidade Federal de Goiás, 74690-900, Goiânia, GO, Brazil; Instituto Federal de Educação, Ciência e Tecnologia de Goiás, Campus Inhumas, 75402-556, Inhumas, GO, Brazil
| | - Federico Figueredo
- Laboratorio de Biosensores y Bioanalisis (LABB), Departamento de Química Biológica e IQUIBICEN-CONICET, Facultad de Ciencias Exactas y Naturales, Universidad de Buenos Aires, CABA, Argentina
| | - Cyro L S Chagas
- Instituto de Química, Universidade de Brasília, 70910-900, Brasília, DF, Brazil
| | - Eduardo Cortón
- Laboratorio de Biosensores y Bioanalisis (LABB), Departamento de Química Biológica e IQUIBICEN-CONICET, Facultad de Ciencias Exactas y Naturales, Universidad de Buenos Aires, CABA, Argentina
| | - Wendell K T Coltro
- Instituto de Química, Universidade Federal de Goiás, 74690-900, Goiânia, GO, Brazil; Instituto Nacional de Ciência e Tecnologia de Bioanalítica, 13084-971, Campinas, SP, Brazil.
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3
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Inaba Y, Yanagisawa T. Droplet dynamics affecting the shape of patterns formed spontaneously by transforming UV-curable emulsions. Sci Rep 2024; 14:7102. [PMID: 38531979 DOI: 10.1038/s41598-024-57851-z] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/10/2023] [Accepted: 03/22/2024] [Indexed: 03/28/2024] Open
Abstract
Forming large pitch and depth patterns spontaneously based on a bottom-up approach is a challenging task but with great industrial value. It is possible to spontaneously form an uneven (concave-convex) patterns with submillimeter-to-millimeter-scale pitches and depths by the direct pattern exposure of a UV-curable oil-in-water (O/W) emulsion liquid film. UV irradiation generates a latent pattern of a cured particle aggregation in the liquid film, and an uneven structure is spontaneously formed during the subsequent drying process. This process does not require any printing and embossing plates or development process. In this report, we presented an example of unevenness formation with a maximum pattern depth of approximately 0.4 mm and a maximum pitch width of 5 mm. The patterns formed by this method have raised edges in the exposed areas and fogging in unexposed areas. The pattern shapes become conspicuous under overexposure conditions, but the formation mechanism has not yet been understood in detail and needs to be investigated. In this study, we focused on the exposure process and clarified the mechanism of pattern formation by analyzing the dynamics of emulsion droplets in the medium by an in situ microscopy observation method. As a result, we found that the fogging was mainly caused by light leakage from the exposed area, and the raised pattern edges were caused by droplets transported from the unexposed area to the exposed area. Furthermore, the convection caused by the heat generated from polymerization is a determining factor affecting all these phenomena. By controlling the pattern shape related to convection utilizing direct projection exposure, we showed an example of eliminating raised pattern edges with a height difference of approximately 0.1 mm. By devising and selecting exposure methods, we can expand the range of design applications such as interior decorative patterns.
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Affiliation(s)
- Yoshimi Inaba
- Toppan Technical Research Institute, TOPPAN Holdings Inc., Sugito, Saitama, 345-8508, Japan.
| | - Takayuki Yanagisawa
- Toppan Technical Research Institute, TOPPAN Holdings Inc., Sugito, Saitama, 345-8508, Japan
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4
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Román-Manso B, Weeks RD, Truby RL, Lewis JA. Embedded 3D Printing of Architected Ceramics via Microwave-Activated Polymerization. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2023; 35:e2209270. [PMID: 36658462 DOI: 10.1002/adma.202209270] [Citation(s) in RCA: 2] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 10/08/2022] [Revised: 01/14/2023] [Indexed: 06/17/2023]
Abstract
Light- and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of one or more oxide materials. This integrated manufacturing method opens new avenues for the design and fabrication of complex ceramic architectures with programmed composition, density, and form for myriad applications.
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Affiliation(s)
- Benito Román-Manso
- John A. Paulson School of Engineering and Applied Sciences and the Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Robert D Weeks
- John A. Paulson School of Engineering and Applied Sciences and the Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Ryan L Truby
- John A. Paulson School of Engineering and Applied Sciences and the Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
| | - Jennifer A Lewis
- John A. Paulson School of Engineering and Applied Sciences and the Wyss Institute for Biologically Inspired Engineering, Harvard University, Cambridge, MA, 02138, USA
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Carpenter JA, Saraw Z, Schwegler A, Magrini T, Kuhn G, Rafsanjani A, Studart AR. Hierarchical Porous Monoliths of Steel with Self-Reinforcing Adaptive Properties. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2023; 35:e2207181. [PMID: 36373556 DOI: 10.1002/adma.202207181] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 08/07/2022] [Revised: 10/07/2022] [Indexed: 06/16/2023]
Abstract
Porous structures offer an attractive approach to reduce the amount of natural resources used while maintaining relatively high mechanical efficiency. However, for some applications the drop in mechanical properties resulting from the introduction of porosity is too high, which has limited the broader utilization of porous materials in industry. Here, it is shown that steel monoliths can be designed to display high mechanical efficiency and reversible self-reinforcing properties when made with porous architectures with up to three hierarchical levels. Ultralight steel structures that can float on water and autonomously adapt their stiffness are manufactured by the thermal reduction and sintering of 3D printed foam templates. Using distinct mechanical testing techniques, image analysis, and finite element simulations, the mechanisms leading to the high mechanical efficiency and self-stiffening ability of the hierarchical porous monoliths are studied. The design and fabrication of mechanically stable porous monoliths using iron as a widely available natural resource is expected to contribute to the future development of functional materials with a more sustainable footprint.
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Affiliation(s)
- Julia A Carpenter
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - Zoubeir Saraw
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - Alain Schwegler
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - Tommaso Magrini
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
- Department of Mechanical and Civil Engineering, California Institute of Technology, Pasadena, CA, 91125, USA
| | - Gisela Kuhn
- Institute for Biomechanics, Department of Health Sciences and Technology, ETH Zürich, Zürich, 8093, Switzerland
| | - Ahmad Rafsanjani
- Center for Soft Robotics, SDU Biorobotics, The Maersk McKinney Moller Institute, University of Southern Denmark, Odense, 5230, Denmark
| | - André R Studart
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
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6
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Kleger N, Fehlmann S, Lee SS, Dénéréaz C, Cihova M, Paunović N, Bao Y, Leroux JC, Ferguson SJ, Masania K, Studart AR. Light-Based Printing of Leachable Salt Molds for Facile Shaping of Complex Structures. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2022; 34:e2203878. [PMID: 35731018 DOI: 10.1002/adma.202203878] [Citation(s) in RCA: 4] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Subscribe] [Scholar Register] [Received: 04/29/2022] [Revised: 06/09/2022] [Indexed: 06/15/2023]
Abstract
3D printing is a powerful manufacturing technology for shaping materials into complex structures. While the palette of printable materials continues to expand, the rheological and chemical requisites for printing are not always easy to fulfill. Here, a universal manufacturing platform is reported for shaping materials into intricate geometries without the need for their printability, but instead using light-based printed salt structures as leachable molds. The salt structures are printed using photocurable resins loaded with NaCl particles. The printing, debinding, and sintering steps involved in the process are systematically investigated to identify ink formulations enabling the preparation of crack-free salt templates. The experiments reveal that the formation of a load-bearing network of salt particles is essential to prevent cracking of the mold during the process. By infiltrating the sintered salt molds and leaching the template in water, complex-shaped architectures are created from diverse compositions such as biomedical silicone, chocolate, light metals, degradable elastomers, and fiber composites, thus demonstrating the universal, cost-effective, and sustainable nature of this new manufacturing platform.
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Affiliation(s)
- Nicole Kleger
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - Simona Fehlmann
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - Seunghun S Lee
- Institute for Biomechanics, Department of Health Science and Technology, ETH Zürich, Zürich, 8093, Switzerland
| | - Cyril Dénéréaz
- Laboratory of Mechanical Metallurgy, Institute of Materials, EPFL Lausanne, Lausanne, 1015, Switzerland
| | | | - Nevena Paunović
- Institute of Pharmaceutical Sciences, Department of Chemistry and Applied Biosciences, ETH Zürich, Zürich, 8093, Switzerland
| | - Yinyin Bao
- Institute of Pharmaceutical Sciences, Department of Chemistry and Applied Biosciences, ETH Zürich, Zürich, 8093, Switzerland
| | - Jean-Christophe Leroux
- Institute of Pharmaceutical Sciences, Department of Chemistry and Applied Biosciences, ETH Zürich, Zürich, 8093, Switzerland
| | - Stephen J Ferguson
- Institute for Biomechanics, Department of Health Science and Technology, ETH Zürich, Zürich, 8093, Switzerland
| | - Kunal Masania
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
| | - André R Studart
- Complex Materials, Department of Materials, ETH Zürich, Zürich, 8093, Switzerland
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7
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Interparticle photo-cross-linkable Pickering emulsions for rapid manufacturing of complex-structured porous ceramic materials. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103638] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/18/2022]
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8
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Blyweert P, Nicolas V, Fierro V, Celzard A. Experimental Design Optimization of Acrylate-Tannin Photocurable Resins for 3D Printing of Bio-Based Porous Carbon Architectures. MOLECULES (BASEL, SWITZERLAND) 2022; 27:molecules27072091. [PMID: 35408490 PMCID: PMC9000739 DOI: 10.3390/molecules27072091] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 02/16/2022] [Revised: 03/22/2022] [Accepted: 03/22/2022] [Indexed: 11/16/2022]
Abstract
In this work, porous carbons were prepared by 3D printing formulations based on acrylate-tannin resins. As the properties of these carbons are highly dependent on the composition of the precursor, it is essential to understand this effect to optimise them for a given application. Thus, experimental design was applied, for the first time, to carbon 3D printing. Using a rationalised number of experiments suggested by a Scheffé mixture design, the experimental responses (the carbon yield, compressive strength, and Young's modulus) were modelled and predicted as a function of the relative proportions of the three main resin ingredients (HDDA, PETA, and CN154CG). The results revealed that formulations containing a low proportion of HDDA and moderate amounts of PETA and CN154CG gave the best properties. Thereby, the optimised carbon structures had a compressive strength of over 5.2 MPa and a Young's modulus of about 215 MPa. The reliability of the model was successfully validated through optimisation tests, proving the value of experimental design in developing customisable tannin-based porous carbons manufactured by stereolithography.
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