Design of textured multi-layered structures via magnetically assisted slip casting

Key influence factors in magneto-controlled motion of micro-nano graphite flakes

Magneto-controlling micro-nano materials' motion is a promising way that enable the noncontact, remote, and nondestructive controlling of their macrostructure as well as functionalities. Here, an optical microscope with an electromagnet was constructed toin-situmonitor the magneto-controlled motion process microscopically. Taking micro-nano graphite flake (MGF) as a model system, we experimentally demonstrate the key factors that influence the magneto-controlling of materials' motion. First, the product of intensity and gradient of the magnetic field (B∇B) has been confirmed as the dominant driving force and the flipping direction of the MGFs is accordingly determined by the vector direction ofB×∇B. Second, quantitatively comparative experiments further revealed that the threshold driving force has an exponential relationship with the structural aspect ratio (b/a) of MGFs. Third, the critical magneto-driving force is found as proportional to the viscosity of the solvent. Accordingly, a dynamic model is developed that describes the flip of the diamagnetic flake under external magnetic field excitation considering the shape factor. It is shown experimentally that the model accurately predicts the flip dynamics of the flake under different magnetic field conditions. In addition, we also discovered the delay effect, multiple cycle acceleration effect, and the fatigue effects due to gas adsorption in magneto-controlled MGFs flipping. These findings can be used to achieve magneto-controlling materials' macrostructure as well as their functionalities.

Thermal Rectification in Modularly Designed Bulk Metamaterials

Thermal rectification is a phenomenon of great practical importance where heat transfer is preferential in one direction. Programmable control of heat transfer in 3D space is key to enable thermal rectification at the macroscale but is rarely realized in natural materials or in current existing devices that are constructed at the nano and microscales with high system complexity. Here, modularly designed bulk metamaterials that can break the symmetry of heat transfer from one direction to the other are created, leading to thermal rectification in convergent or divergent states by tuning the metamaterial microstructural design. These thermal metamaterials are microstructured composites made using one material composition, however, they offer sufficient microstructural design freedom to allow tunable local thermal properties for unusual macroscopic heat transfer. The strategy and performance achieved are promising for next-generation thermal management.

Emerging Magnetic Fabrication Technologies Provide Controllable Hierarchically-Structured Biomaterials and Stimulus Response for Biomedical Applications

Multifunctional nanocomposites which exhibit well-defined physical properties and encode spatiotemporally-controlled responses are emerging as components for advanced responsive systems. For biomedical applications magnetic nanocomposite materials have attracted significant attention due to their ability to respond to spatially and temporally varying magnetic fields. The current state-of-the-art in development and fabrication of magnetic hydrogels toward biomedical applications is described. There is accelerating progress in the field due to advances in manufacturing capabilities. Three categories can be identified: i) Magnetic hydrogelation, DC magnetic fields are used during solidification/gelation for aligning particles; ii) additive manufacturing of magnetic materials, 3D printing technologies are used to develop spatially-encoded magnetic properties, and more recently; iii) magnetic additive manufacturing, magnetic responses are applied during the printing process to develop increasingly complex structural arrangement that may recapitulate anisotropic tissue structure and function. The magnetic responsiveness of conventionally and additively manufactured magnetic hydrogels are described along with recent advances in soft magnetic robotics, and the categorization is related to final architecture and emergent properties. Future challenges and opportunities, including the anticipated role of combinatorial approaches in developing 4D-responsive functional materials for tackling long-standing problems in biomedicine including production of 3D-specified responsive cell scaffolds are discussed.

Microstructured BN Composites with Internally Designed High Thermal Conductivity Paths for 3D Electronic Packaging

Miniaturized and high-power-density 3D electronic devices pose new challenges on thermal management. Indeed, prompt heat dissipation in electrically insulating packaging is currently limited by the thermal conductivity achieved by thermal interface materials (TIMs) and by their capability to direct the heat toward heat sinks. Here, high thermal conductivity boron nitride (BN)-based composites that are able to conduct heat intentionally toward specific areas by locally orienting magnetically functionalized BN microplatelets are created using magnetically assisted slip casting. The obtained thermal conductivity along the direction of alignment is unusually high, up to 12.1 W m^-1 K^-1 , thanks to the high concentration of 62.6 vol% of BN in the composite, the low concentration in polymeric binder, and the high degree of alignment. The BN composites have a low density of 1.3 g cm^-3 , a high stiffness of 442.3 MPa, and are electrically insulating. Uniquely, the approach is demonstrated with proof-of-concept composites having locally graded orientations of BN microplatelets to direct the heat away from two vertically stacked heat sources. Rationally designing the microstructure of TIMs to direct heat strategically provides a promising solution for efficient thermal management in 3D integrated electronics.

Magnetically assisted drop-on-demand 3D printing of microstructured multimaterial composites

Microstructured composites with hierarchically arranged fillers fabricated by three-dimensional (3D) printing show enhanced properties along the fillers’ alignment direction. However, it is still challenging to achieve good control of the filler arrangement and high filler concentration simultaneously, which limits the printed material’s properties. In this study, we develop a magnetically assisted drop-on-demand 3D printing technique (MDOD) to print aligned microplatelet reinforced composites. By performing drop-on-demand printing using aqueous slurry inks while applying an external magnetic field, MDOD can print composites with microplatelet fillers aligned at set angles with high filler concentrations up to 50 vol%. Moreover, MDOD allows multimaterial printing with voxelated control. We showcase the capabilities of MDOD by printing multimaterial piezoresistive sensors with tunable performances based on the local microstructure and composition. MDOD thus creates a large design space to enhance the mechanical and functional properties of 3D printed electronic or sensing devices using a wide range of materials.

3D printed composites with hierarchically arranged fillers have been challenging to fabricate. Here, the authors make use of magnetically assisted droplet-based printing to 3D print voxelated structures with high filler content, localized control of filler material, and orientation.

Magnetically driven in-plane modulation of the 3D orientation of vertical ferromagnetic flakes

External magnetic fields are known to attract and orient magnetically responsive colloidal particles. In the case of 2D microplatelets, rotating magnetic fields are typically used to orient them parallel to each other in a brick-and-mortar fashion. Thanks to this microstructure, the resulting composites achieve enhanced mechanical and functional properties. However, parts with complex geometries require their microstructure to be specifically tuned and controlled locally in 3D. Although the tunability of the microstructure along the vertical direction has already been demonstrated using magnetic orientation combined with sequential or continuous casting, controlling the particle orientation in the horizontal plane in a fast and effective fashion remains challenging. Here, we propose to use rotating magnetic arrays to control the in-plane orientation of ferromagnetic nickel flakes distributed in curable polymeric matrices. We experimentally studied the orientation of the flakes in response to magnets rotating at various frequencies and precessing angles. Then, we used COMSOL to model the magnetic field from rotating magnetic arrays and predicted the resulting in-plane orientations. To validate the approach, we created composites with locally oriented flakes. This work could initiate reverse-engineering methods to design the microstructure in composite materials with intricate geometrical shapes for structural or functional applications.

Cellulose-Based Microparticles for Magnetically Controlled Optical Modulation and Sensing

Responsive materials with birefringent optical properties have been exploited for the manipulation of light in several modern electronic devices. While electrical fields are often utilized to achieve optical modulation, magnetic stimuli may offer an enticing complementary approach for controlling and manipulating light remotely. Here, the synthesis and characterization of magnetically responsive birefringent microparticles with unusual magneto-optical properties are reported. These functional microparticles are prepared via a microfluidic emulsification process, in which water-based droplets are generated in a flow-focusing device and stretched into anisotropic shapes before conversion into particles via photopolymerization. Birefringence properties are achieved by aligning cellulose nanocrystals within the microparticles during droplet stretching, whereas magnetic responsiveness results from the addition of superparamagnetic nanoparticles to the initial droplet template. When suspended in a fluid, the microparticles can be controllably manipulated via an external magnetic field to result in unique magneto-optical coupling effects. Using a remotely actuated magnetic field coupled to a polarized optical microscope, these microparticles can be employed to convert magnetic into optical signals or to estimate the viscosity of the suspending fluid through magnetically driven microrheology.