Nanoscale coaxial focused electrohydrodynamic jet printing

A novel semi-flexible coaxial nozzle based on fluid dynamics effects and its self-centering performance study

Coaxial nozzles are widely used to produce fibers with core-shell structures. However, conventional coaxial nozzles cannot adjust the coaxiality of the inner and outer needles in real-time during the fiber production process, resulting in uneven fiber wall thickness and poor quality. Therefore, we proposed an innovative semi-flexible coaxial nozzle with a dynamic self-centering function. This new design addresses the challenge of ensuring the coaxiality of the inner and outer needles of the coaxial nozzle. First, based on the principles of fluid dynamics and fluid-structure interaction, a self-centering model for a coaxial nozzle is established. Second, the influence of external fluid velocity and inner needle elastic modulus on the centering time and coaxiality error is analyzed by finite element simulation. Finally, the self-centering performance of the coaxial nozzle is verified by observing the coaxial extrusion process online and measuring the wall thickness of the formed hollow fiber. The results showed that the coaxiality error increased with the increase of Young's modulus E and decreased with the increase of flow velocity. The centering time required for the inner needle to achieve force balance decreases with the increase of Young's modulus ( E ) and fluid velocity ( v f ). The nozzle exhibits significant self-centering performance, dynamically reducing the initial coaxiality error from 380 to 60 μm within 26 s. Additionally, it can mitigate the coaxiality error caused by manufacturing and assembly precision, effectively controlling them within 8 μm. Our research provides valuable references and solutions for addressing issues such as uneven fiber wall thickness caused by coaxiality errors.

Multifunctional Nanofibrous Scaffolds Capable of Localized Delivery of Theranostic Nanoparticles for Postoperative Cancer Management

Postoperative recovery of cancer patients can be affected by complications, such as tissue dysfunction or disability caused by tissue resection, and also cancer recurrence resulting from residual cancer cells. Despite impressive progress made for tissue engineering scaffolds that assist tissue regeneration for postoperative cancer patients, the majority of existing tissue engineering scaffolds still lack functions for monitoring and killing residual cancer cells, if there are any, upon their detection. In this study, multifunctional scaffolds that comprise biodegradable nanofibers and core-shell structured microspheres encapsulated with theranostic nanoparticles (NPs) are developed. The multifunctional scaffolds possess an extracellular matrix-like nanofibrous architecture and soft tissue-like mechanical properties, making them excellent tissue engineering patch candidates for assisting in the repair and regeneration of tissues at the cancerous sites after surgery. Furthermore, they are capable of localized delivery of theranostic NPs upon quick degradation of core-shell structured microspheres that contain theranostic NPs. Leveraging on folic acid-mediated ligand-receptor binding, surface-enhanced Raman scattering activity, and near-infrared-responsive photothermal effect of the theranostic gold NPs (AuNPs) delivered locally, the multifunctional scaffolds display excellent active targeting, diagnosis, and photothermal therapy functions for cancer cells, showing great promise for adaptive postoperative cancer management.

High-performance flexible organic field effect transistors with print-based nanowires

Polymer nanowire (NW) organic field-effect transistors (OFETs) integrated on highly aligned large-area flexible substrates are candidate structures for the development of high-performance flexible electronics. This work presents a universal technique, coaxial focused electrohydrodynamic jet (CFEJ) printing technology, to fabricate highly aligned 90-nm-diameter polymer arrays. This method allows for the preparation of uniformly shaped and precisely positioned nanowires directly on flexible substrates without transfer, thus ensuring their electrical properties. Using indacenodithiophene-co-benzothiadiazole (IDT-BT) and poly(9,9-dioctylfluorene-co-benzothiadiazole) (F8-BT) as example materials, 5 cm2 arrays were prepared with only minute size variations, which is extremely difficult to do using previously reported methods. According to 2D-GIXRD analysis, the molecules inside the nanowires mainly adopted face-on π-stacking crystallite arrangements. This is quite different from the mixed arrangement of thin films. Nanowire-based OFETs exhibited a high average hole mobility of 1.1 cm2 V-1 s-1 and good device uniformity, indicating the applicability of CFEJ printing as a potential batch manufacturing and integration process for high-performance, scalable polymer nanowire-based OFET circuits. This technique can be used to fabricate various polymer arrays, enabling the use of organic polymer semiconductors in large-area, high-performance electronic devices and providing a new path for the fabrication of flexible displays and wearable electronics in the future.

PZT Composite Film Preparation and Characterization Using a Method of Sol-Gel and Electrohydrodynamic Jet Printing

Lead zircon titanate (PZT) composite films were advantageously prepared by a novel hybrid method of sol-gel and electrohydrodynamic jet (E-jet) printing. PZT thin films with thicknesses of 362 nm, 725 nm and 1092 nm were prepared on Ti/Pt bottom electrode via Sol-gel method, and then the PZT thick films were printed on the base of the PZT thin films via E-jet printing to form PZT composite films. The physical structure and electrical properties of the PZT composite films were characterized. The experimental results showed that, compared with PZT thick films prepared via single E-jet printing method, PZT composite films had fewer micro-pore defects. Moreover, the better bonding with upper and lower electrodes and higher preferred orientation of crystals were examined. The piezoelectric properties, dielectric properties and leakage currents of the PZT composite films were obviously improved. The maximum piezoelectric constant of the PZT composite film with a thickness of 725 nm was 69.4 pC/N, the maximum relative dielectric constant was 827 and the leakage current was reduced to 1.5 × 10^-6A at a test voltage of 200V. This hybrid method can be widely useful to print PZT composite films for the application of micro-nano devices.

Optimized coaxial focused electrohydrodynamic jet printing of highly ordered semiconductor sub-microwire arrays for high-performance organic field-effect transistors

Patterning of semiconductor polymers is pertinent to preparing and applying organic field-effect transistors (OFETs). In this study, coaxial focused electrohydrodynamic jet printing (high resolution, high speed, and convenient) was used to pattern polymer semiconductors. The influence of the key printing parameters on the width of polymer sub-microwires was evaluated. The width decreased with increasing applied voltage, printing speed, and concentration of the polymer ink. However, the width increased gradually with increasing polymer ink flow rate. A regression analysis model of the relationship between the printing parameters and width was established. Based on a regression analysis/genetic algorithm, the optimal printing parameters were obtained and the correctness of the printing parameters was verified. The optimized printing parameters stabilized the width of the arrays to ca. 110 nm and imparted a smooth morphology. Additionally, the corresponding OFETs exhibited a high mobility of 2 cm² V^-1 s^-1, which is 5× higher than that of thin-film-based OFETs. One can conveniently obtain high-performance OFETs from ordered sub-microwire arrays fabricated by CFEJ printing.

Large area polymer semiconductor sub-microwire arrays by coaxial focused electrohydrodynamic jet printing for high-performance OFETs

Large area and highly aligned polymer semiconductor sub-microwires were fabricated using the coaxial focused electrohydrodynamic jet printing technology. As indicated by the results, the sub-microwire arrays have smooth morphology, well reproducibility and controllable with a width of ~110 nm. Analysis shows that the molecular chains inside the sub-microwires mainly exhibited edge-on arrangement and the π-stacking direction (010) of the majority of crystals is parallel to the long axis of the sub-microwires. Sub-microwires based organic field effect transistors showed high mobility with an average of 1.9 cm² V⁻¹ s⁻¹, approximately 5 times higher than that of thin film based organic field effect transistors. In addition, the number of sub-microwires can be conveniently controlled by the printing technique, which can subsequently concisely control the performance of organic field effect transistors. This work demonstrates that sub-microwires fabricated by the coaxial focused electrohydrodynamic jet printing technology create an alternative path for the applications of high-performance organic flexible device.

Here, the authors fabricate large area and highly aligned polymer semiconductor sub-microwires arrays via coaxial focused electrohydrodynamic jet printing technology, achieving high on/off ratio and average mobility that is 5x higher than that of thin film based organic field effect transistors.

Mode-tunable, micro/nanoscale electrohydrodynamic deposition techniques for optoelectronic device fabrication

The rapid development of fascinating new optoelectronic materials and devices calls for the innovative production of micro/nanostructures in a high-resolution, large-scale, low-cost fashion, preferably compatible with flexible/wearable applications. Powerful electrohydrodynamic (EHD) deposition techniques, which generate micro/nanostructures using high electrical forces, exhibit unique advantages in high printing resolution (<1 μm), tunable printing modes (electrospray for films, electrospinning for fibers and EHD jet printing for dots), and wide material applicability (viscosity 1-10 000 cps), making them attractive in the fabrication of high-density and high-tech optoelectronic devices. This review highlights recent advances related to EHD-deposited optoelectronics, ranging from solar cells, photodetectors, and light-emitting diodes, to transparent electrodes, with detailed descriptions of the EHD-based jetting mechanism, ink formulation requirements and corresponding jetting modes to obtain functional micro/nanostructures. Finally, a brief summary and an outlook on the future perspectives are proposed.

Numerical modeling and analysis of coaxial electrohydrodynamic jet printing

Coaxial electrohydrodynamic jet (CE-Jet) printing is an encouraging method for fabrication of high-resolution micro and nanostructures in MEMS systems. This paper presents a novel simulation work based on phase field method which is considered as a precise technique in fluid dynamics. The study explores influence of various parameters such as applied voltage, needle-substrate distance, dynamic viscosity, relative permittivity, needle size and flow rate on stability and resolution of CE-Jet morphologies. The morphology of CE-Jet exhibits that width of cone-jet profile and printed structures on substrate were directly proportional to relative permittivity and flow rate. In addition, it was inversely proportional to dynamic viscosity and applied voltage. The study examine that CE-Jet length of inner liquid is inversely proportional to needle-substrate distance in same time. It was later verified in experimental study by producing stable CE-Jet morphology with 300 μm diameter using optimized parameters (i.e., DC voltage 7.0 kV and inner liquid flow rate 400 nl/min) as compared to other validation studies such as 400 μm and 500 μm. The CE-Jet printing technique investigates significant changes in consistency and stability of CE-Jet morphologies and makes Jet unique and comparable when adjustment accuracy reaches 0.01 mm. PZT sol line structures with a diameter of 1 µm were printed directly on substrate using inner needle (diameter of 120 µm). Therefore, it is considered as a powerful tool for nano constructs production in M/NEMS devices.

Microtip focused electrohydrodynamic jet printing with nanoscale resolution

Electrohydrodynamic jet (E-Jet) printing is a promising manufacturing technique for micro-/nano-patterned structures with high resolution, high efficiency and high material compatibility. However, further improvement of the necking ratio of the E-Jet is still limited by the focusing principle. Moreover, ink viscosity is limited to values well below 90 mPa s owing to the high probability of nozzle blockage. Here, we propose a microtip focused electrohydrodynamic jet (MFEJ) printing to overcome these limitations. This technique uses a solid microtip with a radius of curvature (ROC) of several micrometers rather than a hollow nozzle, which is very simple and highly efficient to prepare and can effectively avoid nozzle clogging problems even with high-viscosity printing ink. High-resolution patterns in diverse geometries were printed using different inks with a wide range of viscosities (8.4-3500 mPa s). Nanodroplets with an average diameter of 73 nm were achieved. Moreover, nanofibers with a diameter of 30 nm were obtained using a 4 μm ROC microtip and the necking ratio was as high as 266 : 1. To the best of our knowledge, this is the smallest droplet or fiber diameter directly obtained via E-Jet printing to date without further physical or chemical processing. This MFEJ printing technique can improve printing resolution at the nanoscale, significantly enlarge the material applicability and effectively avoid nozzle clogging for the fabrication of nanodevices.

3D electrohydrodynamic printing and characterisation of highly conductive gold nanowalls

3D printing research targets the creation of nanostructures beyond the limits of traditional micromachining. A proper characterisation of their functionalities is necessary to facilitate future implementation into applications. We fabricate, in an open atmosphere, high-aspect-ratio gold nanowalls by electrohydrodynamic rapid nanodripping, and comprehensively analyse their electronic performance by four-point probe measurements. We reveal the large-grained nanowall morphology by transmission electron microscopy and explain the measured low resistivities approaching those of bulk gold. This work is a significant advancement in contactless bottom-up 3D nanofabrication and characterisation and could also serve as a platform for fundamental studies of additively manufactured high-aspect-ratio out-of-plane metallic nanostructures.

Electrohydrodynamics of droplets and jets in multiphase microsystems

Electrohydrodynamics is among the most promising techniques for manipulating liquids in microsystems. The electric stress actuates, generates, and coalesces droplets of small sizes; it also accelerates, focuses, and controls the motion of fine jets. In this review, the current understanding of dynamic regimes of electrically driven drops and jets in multiphase microsystems is summarized. The experimental description and underlying mechanism of force interplay and instabilities are discussed. Conditions for controlled transitions among different regimes are also provided. Emerging new phenomena either due to special interfacial properties or geometric confinement are emphasized, and simple scaling arguments proposed in the literature are introduced. The review provides useful perspectives for investigations involving electrically driven droplets and jets.

Sacrificial layer-assisted nanoscale transfer printing

Transfer printing is an emerging assembly technique for flexible and stretchable electronics. Although a variety of transfer printing methods have been developed, transferring patterns with nanometer resolution remains challenging. We report a sacrificial layer-assisted nanoscale transfer printing method. A sacrificial layer is deposited on a donor substrate, and ink is prepared on and transferred with the sacrificial layer. Introducing the sacrificial layer into the transfer printing process eliminates the effect of the contact area on the energy release rate (ERR) and ensures that the ERR for the stamp/ink-sacrificial layer interface is greater than that for the sacrificial layer/donor interface even at a slow peel speed (5 mm s-1). Hence, large-area nanoscale patterns can be successfully transferred with a yield of 100%, such as Au nanoline arrays (100 nm thick, 4 mm long and 47 nm wide) fabricated by photolithography techniques and PZT nanowires (10 mm long and 63 nm wide) fabricated by electrohydrodynamic jet printing, using only a blank stamp and without the assistance of any interfacial chemistries. Moreover, the presence of the sacrificial layer also enables the ink to move close to the mechanical neutral plane of the multilayer peel-off sheet, remarkably decreasing the bending stress and obviating cracks or fractures in the ink during transfer printing.

Advanced Nanomaterials, Printing Processes, and Applications for Flexible Hybrid Electronics

Recent advances in nanomaterial preparation and printing technologies provide unique opportunities to develop flexible hybrid electronics (FHE) for various healthcare applications. Unlike the costly, multi-step, and error-prone cleanroom-based nano-microfabrication, the printing of nanomaterials offers advantages, including cost-effectiveness, high-throughput, reliability, and scalability. Here, this review summarizes the most up-to-date nanomaterials, methods of nanomaterial printing, and system integrations to fabricate advanced FHE in wearable and implantable applications. Detailed strategies to enhance the resolution, uniformity, flexibility, and durability of nanomaterial printing are summarized. We discuss the sensitivity, functionality, and performance of recently reported printed electronics with application areas in wearable sensors, prosthetics, and health monitoring implantable systems. Collectively, the main contribution of this paper is in the summary of the essential requirements of material properties, mechanisms for printed sensors, and electronics.

Configuration optimization of bionic piezoelectric hair sensor for acoustic/tactile detection

Specialized sensory hairs are important biological sensors for arthropods to detect and recognize environmental conditions including acoustic, pressure and airflow signals. However, the present design methodology of such biomimic micro devices are mainly depending on shape mimicking, which greatly restricts their performance. In this paper, a novel genetic algorithm based optimization model for design of piezoelectric functional hair is developed for improving its acoustic pressure or tactile sensitivity. Furthermore, the sensing mechanism of axially polarized piezoelectric hair is explored and the main influencing factors on sensitivity including hair configuration and axial strain distribution are determined. Then, a series of optimized hair configurations are obtained in a specific frequency band from 1 Hz to 500 Hz, whose average sensitivity of 2.21 × 10^-3 V Pa^-1 is 10 times greater than that of the straight hair of 2.15 × 10^-4 V Pa^-1 with the same size. For tactile load detection, the output voltage of the optimized hair is about 1.5 times as much as that of the straight hair. The obtained hairs are similar with the spider's trichobothria and tactile hair, which presents an explanation of biological hairs sensitive to dynamic and static loads.

Ultra-thin carbon nanofibers based on graphitization of near-field electrospun polyacrylonitrile

A novel manufacturing means for arrays of carbon fibers with diameters less than 10 nm has been developed. The method improves dramatically upon the state of the art of making carbon fibers by pyrolysis of near field electrospun (NFES) polyacrylonitrile (PAN) fibers. The conductive nature of the PAN ink, touch and retract mode of the droplet at the ejector needle tip and a rotating drum for jet initiation as well as a tight control of the ink flow and droplet shape with a porous paper enable continuous near field electrospinning at an ultra-low voltage of 35 V - far below current low-voltage NFES practice. By pyrolyzing the thus obtained thinner PAN nanofibers on carbon scaffolds, a dramatic further shrinkage of the diameter leads to ultrathin carbon nanofibers e.g. from an ∼245 nm polymer fiber to an ∼5 nm carbon fiber i.e. a 4900% reduction in fiber diameter. To increase and survive the thinning during the pyrolysis process, PAN stabilization at a relatively low temperature (115 °C) and carbon support scaffolds are implemented to provide just the right amount of tension of the suspended polymer nanofibers. A small inter-fiber spacing (<8 μm) of the ultrathin carbon fibers in an array is achieved by simultaneously controlling the linear speed of the spinneret and the rotational speed of the collector. In one application, we demonstrate aligned ultra-thin carbon fibers freely suspended and in good ohmic contact with carbon scaffolds on a silicon substrate.

Electrohydrodynamic-Jet (EHD)-Printed Diketopyrrolopyroole-Based Copolymer for OFETs and Circuit Applications

We report the employment of an electrohydrodynamic-jet (EHD)-printed diketopyrrolopyrrole-based copolymer (P-29-DPPDTSE) as the active layer of fabricated organic field-effect transistors (OFETs) and circuits. The device produced at optimal conditions showed a field-effect mobility value of 0.45 cm²/(Vs). The morphologies of the printed P-29-DPPDTSE samples were determined by performing optical microscopy, X-ray diffraction, and atomic force microscopy experiments. In addition, numerical circuit simulations of the optimal printed P-29-DPPDTSE OFETs were done in order to observe how well they would perform in a high-voltage logic circuit application. The optimal printed P-29-DPPDTSE OFET showed a 0.5 kHz inverter frequency and 1.2 kHz ring oscillator frequency at a 40 V supply condition, indicating the feasibility of its use in a logic circuit application at high voltage.