Co-Assembly of Soft and Hard Nanoparticles into Macroscopic Colloidal Composites with Tailored Mechanical Property and Processability

Colloidal composites, translating the great potential of nanoscale building bricks into macroscopic dimensions, have emerged as an appealing candidate for new materials with applications in optics, energy storage, and biomedicines. However, it remains a key challenge to bridge the size regimes from nanoscopic colloidal particles to macroscale composites possessing mechanical robustness. Herein, a bottom-up approach is demonstrated to manufacture colloidal composites with customized macroscopic forms by virtue of the co-assembly of nanosized soft polymeric micelles and hard inorganic nanoparticles. Upon association, the hairy micellar corona can bind with the hard nanoparticles, linking individual hard constituents together in a soft-hard alternating manner to form a collective entity. This permits the integration of block copolymer micelles with controlled amounts of hard nanoparticles into macroscopic colloidal composites featuring diverse internal microstructures. The resultant composites showed tunable microscale mechanical strength in a range of 90-270 MPa and macroscale mechanical strength in a range of 7-42 MPa for compression and 2-24 MPa for bending. Notably, the incorporation of soft polymeric micelles also imparts time- and temperature-dependent dynamic deformability and versatile capacity to the resulting composites, allowing their application in the low-temperature plastic processing for functional fused silica glass.

Atomic surface of quartz glass induced by photocatalytic green chemical mechanical polishing using the developed SiO2@TiO2 core-shell slurry

High-performance devices of quartz glass demand an atomic surface, which induces a challenge for chemical mechanical polishing (CMP) with a high material removal rate (MRR). Moreover, traditional CMP usually employs toxic and corrosive slurries, leading to the pollution of the environment. To overcome these challenges, a novel green photocatalytic CMP is proposed. In the CMP, SiO2@TiO2 core-shell abrasives were developed, and the CMP slurry included the developed abrasives, sodium carbonate, hydrogen peroxide and sorbitol. After photocatalytic CMP, the surface roughness Sa of quartz glass is 0.185 nm, with a scanning area of 50 × 50 μm2, and the MRR is 8.64 μm h-1. To the best of our knowledge, the MRR is the highest on such a big area of atomic surface for quartz glass. X-ray photoelectron spectroscopy reveals that SiO2@TiO2 core-shell abrasives were used as photocatalysts motivated by simulated solar light, generating electrons and holes and producing hydroxyl radicals through hydrogen peroxide. As a result, OH- could combine with Si atoms on the surface of quartz glass, forming Si-OH-Si bonds. Then the formed bonds were removed based on the balance between chemical and mechanical functions. The proposed CMP, developed SiO2@TiO2 abrasives and slurry provide new insights to achieve an atomic surface of quartz glass with a high MRR.

Metasurface inverse designed by deep learning for quasi-entire terahertz wave absorption

Ultra-broadband and efficient terahertz (THz) absorption is of paramount importance for the development of high-performance detectors. These detectors find applications in next-generation wireless communications, military radar systems, security detection, medical imaging, and various other domains. In this study, we present an ultra-wideband THz wave metasurface absorber (UTWMA) featuring a composite surface microstructure and a multilayer absorbing material (graphene). This UTWMA demonstrates remarkable capabilities by achieving highly efficient absorption levels, reaching 96.33%, within the 0.5-10 THz frequency range. To enhance the efficiency and precision of the design process, we have incorporated artificial neural networks, which enable rapid and accurate parameter selection. Moreover, we have conducted a comprehensive analysis of the absorption mechanism exhibited by the UTWMA at different frequencies. This analysis combines insights from the electric field distribution and effective medium theory. The findings presented in this paper are expected to catalyze further research in the domain of broadband THz technology, particularly in the context of metasurfaces and related fields. Additionally, this work paves the way for the development of compact, supercontinuous THz photovoltaic or photothermal electrical devices.

Room-Temperature Molding of Complex-Shaped Transparent Fused Silica Lenses

The high hardness, brittleness, and thermal resistance impose significant challenges in the scalable manufacturing of fused silica lenses, which are widely used in numerous applications. Taking advantage of the nanocomposites by stirring silica nanopowders with photocurable resins, the newly emerged low-temperature pre-shaping technique provides a paradigm shift in fabricating transparent fused silica components. However, preparing the silica slurry and carefully evaporating the organics may significantly increase the process complexity and decrease the manufacturing efficiency for the nanocomposite-based technique. By directly pressing pure silica nanopowders against the complex-shaped metal molds in minutes, this work reports an entirely different room-temperature molding method capable of mass replication of complex-shaped silica lenses without organic additives. After sintering the replicated lenses, fully transparent fused silica lenses with spherical, arrayed, and freeform patterns are generated with nanometric surface roughness and well-reserved mold shapes, demonstrating a scalable and cost-effective route surpassing the current techniques for the manufacturing of high-quality fused silica lenses.

Low-temperature 3D printing of transparent silica glass microstructures

Transparent silica glass is one of the most essential materials used in society and industry, owing to its exceptional optical, thermal, and chemical properties. However, glass is extremely difficult to shape, especially into complex and miniaturized structures. Recent advances in three-dimensional (3D) printing have allowed for the creation of glass structures, but these methods involve time-consuming and high-temperature processes. Here, we report a photochemistry-based strategy for making glass structures of micrometer size under mild conditions. Our technique uses a photocurable polydimethylsiloxane resin that is 3D printed into complex structures and converted to silica glass via deep ultraviolet (DUV) irradiation in an ozone environment. The unique DUV-ozone conversion process for silica microstructures is low temperature (~220°C) and fast (<5 hours). The printed silica glass is highly transparent with smooth surface, comparable to commercial fused silica glass. This work enables the creation of arbitrary structures in silica glass through photochemistry and opens opportunities in unexplored territories for glass processing techniques.

Injection Molding of Encapsulated Diffractive Optical Elements

Microstructuring techniques, such as laser direct writing, enable the integration of microstructures into conventional polymer lens systems and may be used to generate advanced functionality. Hybrid polymer lenses combining multiple functions such as diffraction and refraction in a single component become possible. In this paper, a process chain to enable encapsulated and aligned optical systems with advanced functionality in a cost-efficient way is presented. Within a surface diameter of 30 mm, diffractive optical microstructures are integrated in an optical system based on two conventional polymer lenses. To ensure precise alignment between the lens surfaces and the microstructure, resist-coated ultra-precision-turned brass substrates are structured via laser direct writing, and the resulting master structures with a height of less than 0.002 mm are replicated into metallic nickel plates via electroforming. The functionality of the lens system is demonstrated through the production of a zero refractive element. This approach provides a cost-efficient and highly accurate method for producing complicated optical systems with integrated alignment and advanced functionality.

A sinterless, low-temperature route to 3D print nanoscale optical-grade glass

Three-dimensional (3D) printing of silica glass is dominated by techniques that rely on traditional particle sintering. At the nanoscale, this limits their adoption within microsystem technology, which prevents technological breakthroughs. We introduce the sinterless, two-photon polymerization 3D printing of free-form fused silica nanostructures from a polyhedral oligomeric silsesquioxane (POSS) resin. Contrary to particle-loaded sacrificial binders, our POSS resin itself constitutes a continuous silicon-oxygen molecular network that forms transparent fused silica at only 650°C. This temperature is 500°C lower than the sintering temperatures for fusing discrete silica particles to a continuum, which brings silica 3D printing below the melting points of essential microsystem materials. Simultaneously, we achieve a fourfold resolution enhancement, which enables visible light nanophotonics. By demonstrating excellent optical quality, mechanical resilience, ease of processing, and coverable size scale, our material sets a benchmark for micro- and nano-3D printing of inorganic solids.

From Nanoscopic to Macroscopic Materials by Stimuli-Responsive Nanoparticle Aggregation

Stimuli-responsive nanoparticle (NP) aggregation plays an increasingly important role in regulating NP assembly into microscopic superstructures, macroscopic 2D, and 3D functional materials. Diverse external stimuli are widely used to adjust the aggregation of responsive NPs, such as light, temperature, pH, electric, and magnetic fields. Many unique structures based on responsive NPs are constructed including disordered aggregates, ordered superlattices, structural droplets, colloidosomes, and bulk solids. In this review, the strategies for NP aggregation by external stimuli, and their recent progress ranging from nanoscale aggregates, microscale superstructures to macroscale bulk materials along the length scales as well as their applications are summarized. The future opportunities and challenges for designing functional materials through NP aggregation at different length scales are also discussed.

Injection Molding of Magnesium Aluminate Spinel Nanocomposites for High-Throughput Manufacturing of Transparent Ceramics

Transparent ceramics like magnesium aluminate spinel (MAS) are considered the next step in material evolution showing unmatched mechanical, chemical and physical resistance combined with high optical transparency. Unfortunately, transparent ceramics are notoriously difficult to shape, especially on the microscale. Therefore, a thermoplastic MAS nanocomposite is developed that can be shaped by polymer injection molding at high speed and precision. The nanocomposite is converted to dense MAS by debinding, pre-sintering, and hot isostatic pressing yielding transparent ceramics with high optical transmission up to 84 % and high mechanical strength. A transparent macroscopic MAS components with wall thicknesses up to 4 mm as well as microstructured components with single micrometer resolution are shown. This work makes transparent MAS ceramics accessible to modern high-throughput polymer processing techniques for fast and cost-efficient manufacturing of macroscopic and microstructured components enabling a plethora of potential applications from optics and photonics, medicine to scratch and break-resistant transparent windows for consumer electronics.

Rapid Assembly of Cellulose Microfibers into Translucent and Flexible Microfluidic Paper-Based Analytical Devices via Wettability Patterning

Microfluidic paper-based analytical devices (μPADs) are emerging as powerful analytical platforms in clinical diagnostics, food safety, and environmental protection because of their low cost and favorable substrate properties for biosensing. However, the existing top-down fabrication methods of paper-based chips suffer from low resolution (>200 μm). Additionally, papers have limitations in their physical properties (e.g., thickness, transmittance, and mechanical flexibility). Here, we demonstrate a bottom-up approach for the rapid fabrication of heterogeneously controlled paper-based chip arrays. We simply print a wax-patterned microchip with wettability contrasts, enabling automatic and selective assembly of cellulose microfibers to construct predefined paper-based microchip arrays with controllable thickness. This paper-based microchip printing technology is feasible for various substrate materials ranging from inorganic glass to organic polymers, providing a versatile platform for the full range of applications including transparent devices and flexible health monitoring. Our bottom-up printing technology using cellulose microfibers as the starting material provides a lateral resolution down to 42 ± 3 μm and achieves the narrowest channel barrier down to 33 ± 2 μm. As a proof-of-concept demonstration, a flexible paper-based glucose monitor is built for human health care, requiring only 0.3 μL of sample for testing.

Replicative manufacturing of metal moulds for low surface roughness polymer replication

Tool based manufacturing processes like injection moulding allow fast and high-quality mass-market production, but for optical polymer components the production of the necessary tools is time-consuming and expensive. In this paper a process to fabricate metal-inserts for tool based manufacturing with smooth surfaces via a casting and replication process from fused silica templates is presented. Bronze, brass and cobalt-chromium could be successfully replicated from shaped fused silica replications achieving a surface roughnesses of R_q 8 nm and microstructures in the range of 5 µm. Injection moulding was successfully performed, using a commercially available injection moulding system, with thousands of replicas generated from the same tool. In addition, three-dimensional bodies in metal could be realised with 3D-Printing of fused silica casting moulds. This work thus represents an approach to high-quality moulding tools via a scalable facile and cost-effective route surpassing the currently employed cost-, labour- and equipment-intensive machining techniques.

Production of tools for polymer replication in the field of optical applications is still time-consuming and cost-intensive. Here the authors develop an efficient metal casting process, and demonstrate manufacturing of structures of complex shapes with a surface roughness of few nanometres.

Monolithic 3D phase profile formation in glass for spatial and temporal control of optical waves

Optical manufacturing technologies play a central role in modern science and engineering. Progress on both subtractive and additive fabrications is transforming the implementation of optical technologies. Despite the recent advances, modern fabrication still faces challenges in the accuracy, dimension, durability, intensity, and wavelength range. Here we present a direct monolithic 3D phase profile formation in glass and demonstrate its versatile applications for high-accuracy spatial and temporal control of optical waves in the extreme wavelength and intensity domains, direct fabrication of microlenses, and in situ aberration correction for refractive components. These advances and flexibilities will provide a new dimension for high-performance optical design and manufacture and enable novel applications in a broad range of disciplines.

The sustainability of emerging technologies for use in pharmaceutical manufacturing

INTRODUCTION

Sustainability within the pharmaceutical industry is becoming a focal point for many companies, to improve the longevity and social perception of the industry. Both additive manufacturing (AM) and microfluidics (MFs) are continuously progressing, so are far from their optimization in terms of sustainability; hence, it is the aim of this review to highlight potential gaps alongside their beneficial features. Discussed throughout this review also will be an in-depth discussion on the environmental, legal, economic, and social particulars relating to these emerging technologies.

AREAS COVERED

Additive manufacturing (AM) and microfluidics (MFs) are discussed in depth within this review, drawing from up-to-date literature relating to sustainability and circular economies. This applies to both technologies being utilized for therapeutic and analytical purposes within the pharmaceutical industry.

EXPERT OPINION

It is the role of emerging technologies to be at the forefront of promoting a sustainable message by delivering plausible environmental standards whilst maintaining efficacy and economic viability. AM processes are highly customizable, allowing for their optimization in terms of sustainability, from reducing printing time to reducing material usage by removing supports. MFs too are supporting sustainability via reduced material wastage and providing a sustainable means for point of care analysis.

Rapid Manufacturing of Complex-Structured Transparent Silica Glass Materials through a Hybridized Approach of Photo-Curing and Machining from Interparticle Photo-Cross-Linkable Suspensions

The rapid manufacturing of transparent SiO₂ glass components via a hybridized 3D structuring approach for photo-curing and green machining, followed by a fast debinding/sintering process (at a heating rate of 20 °C min^-1), is reported to be based on the design of a new series of interparticle photo-cross-linkable suspensions. In these suspensions, small amounts of multifunctional acrylates and silane alkoxides with acryloyl groups (A-Si) are co-photo-polymerized and further reacted with SiO₂ particles modified using functionalized polyethyleneimine to form hybridized interparticle networks. The addition of A-Si increases the interparticle cross-linking densities, leading to an improvement in the mechanical properties and green machinability of the photo-cured bodies. Furthermore, the A-Si component in the cross-links forms siloxane-based networks among SiO₂ particles in situ during the debinding/sintering process, which increases the mechanical strength of the debinded bodies and successfully prevents structural collapses under rapid heating conditions. The study demonstrates that the photo-cured body from the newly designed suspensions can be green-machined into pillars, microfluids, and assembling blocks and can be sintered into highly transparent SiO₂ glass components. Overall, this work provides new options for the time- and energy-effective processing of SiO₂ glass materials with tailor-made 3D structures.

Melt-Extrusion-Based Additive Manufacturing of Transparent Fused Silica Glass

In recent years, additive manufacturing (AM) of glass has attracted great interest in academia and industry, yet it is still mostly limited to liquid nanocomposite-based approaches for stereolithography, two-photon polymerization, or direct ink writing. Melt-extrusion-based processes, such as fused deposition modeling (FDM), which will allow facile manufacturing of large thin-walled components or simple multimaterial printing processes, are so far inaccessible for AM of transparent fused silica glass. Here, melt-extrusion-based AM of transparent fused silica is introduced by FDM and fused feedstock deposition (FFD) using thermoplastic silica nanocomposites that are converted to transparent glass using debinding and sintering. This will enable printing of previously inaccessible glass structures like high-aspect-ratio (>480) vessels with wall thicknesses down to 250 µm, delicate parts including overhanging features using polymer support structures, as well as dual extrusion for multicolored glasses.

Glass surface as strong base, 'green' heterogeneous catalyst and degradation reagent

Systematic screening of accelerated chemical reactions at solid/solution interfaces has been carried out in high-throughput fashion using desorption electrospray ionization mass spectrometry and it provides evidence that glass surfaces accelerate various base-catalyzed chemical reactions. The reaction types include elimination, solvolysis, condensation and oxidation, whether or not the substrates are pre-charged. In a detailed mechanistic study, we provide evidence using nanoESI showing that glass surfaces can act as strong bases and convert protic solvents into their conjugate bases which then act as bases/nucleophiles when participating in chemical reactions. In aprotic solvents such as acetonitrile, glass surfaces act as ‘green’ heterogeneous catalysts that can be recovered and reused after simple rinsing. Besides their use in organic reaction catalysis, glass surfaces are also found to act as degradation reagents for phospholipids with increasing extents of degradation occurring at low concentrations. This finding suggests that the storage of base/nucleophile-labile compounds or lipids in glass containers should be avoided.

Glass surfaces are found to be strong bases, ‘green’ heterogeneous catalysts and degradation reagents: glass microspheres act as strong bases to accelerate multiple base-catalyzed reaction types by a factor of 26–2021.