Selective Laser Sintering Fabricated Thermoplastic Polyurethane/Graphene Cellular Structures with Tailorable Properties and High Strain Sensitivity

Design and Optimization of NR-Based Stretchable Conductive Composites Filled with MoSi2 Nanoparticles and MWCNTs: Perspectives from Experimental Characterization and Molecular Dynamics Simulations

Stretchable conductive composites play a pivotal role in the development of personalized electronic devices, electronic skins, and artificial implant devices. This article explores the fabrication and characterization of stretchable composites based on natural rubber (NR) filled with molybdenum disilicide (MoSi2) nanoparticles and multi-walled carbon nanotubes (MWCNTs). Experimental characterization and molecular dynamics (MD) simulations are employed to investigate the static and dynamic properties of the composites, including morphology, glass transition temperature (Tg), electrical conductivity, and mechanical behavior. Results show that the addition of MoSi2 nanoparticles enhances the dispersion of MWCNTs within the NR matrix, optimizing the formation of a conductive network. Dynamic mechanical analysis (DMA) confirms the Tg reduction with the addition of MWCNTs and the influence of MoSi2 content on Tg. Mechanical testing reveals that the tensile strength increases with MoSi2 content, with an optimal ratio of 4:1 MoSi2:MWCNTs. Electrical conductivity measurements demonstrate that the MoSi2/MWCNTs/NR composites exhibit enhanced conductivity, reaching optimal values at specific filler ratios. MD simulations further support experimental findings, highlighting the role of MoSi2 in improving dispersion and mechanical properties. Overall, the study elucidates the synergistic effects of nanoparticles and nanotubes in enhancing the properties of stretchable conductive composites.

Piezoresistive Porous Composites with Triply Periodic Minimal Surface Structures Prepared by Self-Resistance Electric Heating and 3D Printing

Three-dimensional flexible piezoresistive porous sensors are of interest in health diagnosis and wearable devices. In this study, conductive porous sensors with complex triply periodic minimal surface (TPMS) structures were fabricated using the 3D printed sacrificial mold and enhancement of MWCNTs. A new curing routine by the self-resistance electric heating was implemented. The porous sensors were designed with different pore sizes and unit cell types of the TPMS (Diamond (D), Gyroid (G), and I-WP (I)). The impact of pore characteristics and the hybrid fabrication technique on the compressive properties and piezoresistive response of the developed porous sensors was studied. The results indicate that the porous sensors cured by the self-resistance electric heating could render a uniform temperature distribution in the composites and reduce the voids in the walls, exhibiting a higher elastic modulus and a better piezoresistive response. Among these specimens, the specimen with the D-based structure cured by self-resistance electric heating showed the highest responsive strain (61%), with a corresponding resistance response value of 0.97, which increased by 10.26% compared to the specimen heated by the external heat sources. This study provides a new perspective on design and fabrication of porous materials with piezoresistive functionalities, particularly in the realm of flexible and portable piezoresistive sensors.

Aortic Valve Engineering Advancements: Precision Tuning with Laser Sintering Additive Manufacturing of TPU/TPE Submillimeter Membranes

Synthetic biomaterials play a crucial role in developing tissue-engineered heart valves (TEHVs) due to their versatile mechanical properties. Achieving the right balance between mechanical strength and manufacturability is essential. Thermoplastic polyurethanes (TPUs) and elastomers (TPEs) garner significant attention for TEHV applications due to their notable stability, fatigue resistance, and customizable properties such as shear strength and elasticity. This study explores the additive manufacturing technique of selective laser sintering (SLS) for TPUs and TPEs to optimize process parameters to balance flexibility and strength, mimicking aortic valve tissue properties. Additionally, it aims to assess the feasibility of printing aortic valve models with submillimeter membranes. The results demonstrate that the SLS-TPU/TPE technique can produce micrometric valve structures with soft shape memory properties, resembling aortic tissue in strength, flexibility, and fineness. These models show promise for surgical training and manipulation, display intriguing echogenicity properties, and can potentially be personalized to shape biocompatible valve substitutes.

Optimization of Piezoresistive Response of Elastomeric Porous Structures Based on Carbon-Based Hybrid Fillers Created by Selective Laser Sintering

Recently, piezoresistive sensors made by 3D printing have gained considerable interest in the field of wearable electronics due to their ultralight nature, high compressibility, robustness, and excellent electromechanical properties. In this work, building on previous results on the Selective Laser Sintering (SLS) of porous systems based on thermoplastic polyurethane (TPU) and graphene (GE)/carbon nanotubes (MWCNT) as carbon conductive fillers, the effect of variables such as thickness, diameter, and porosity of 3D printed disks is thoroughly studied with the aim of optimizing their piezoresistive performance. The resulting system is a disk with a diameter of 13 mm and a thickness of 0.3 mm endowed with optimal reproducibility, sensitivity, and linearity of the electrical signal. Dynamic compressive strength tests conducted on the proposed 3D printed sensors reveal a linear piezoresistive response in the range of 0.1-2 N compressive load. In addition, the optimized system is characterized at a high load frequency (2 Hz), and the stability and sensitivity of the electrical signal are evaluated. Finally, an application test demonstrates the ability of this system to be used as a real-time wearable pressure sensor for applications in prosthetics, consumer products, and personalized health-monitoring systems.

3D Printed Graphene and Graphene/Polymer Composites for Multifunctional Applications

Three-dimensional (3D) printing, alternatively known as additive manufacturing, is a transformative technology enabling precise, customized, and efficient manufacturing of components with complex structures. It revolutionizes traditional processes, allowing rapid prototyping, cost-effective production, and intricate designs. The 3D printed graphene-based materials combine graphene's exceptional properties with additive manufacturing's versatility, offering precise control over intricate structures with enhanced functionalities. To gain comprehensive insights into the development of 3D printed graphene and graphene/polymer composites, this review delves into their intricate fabrication methods, unique structural attributes, and multifaceted applications across various domains. Recent advances in printable materials, apparatus characteristics, and printed structures of typical 3D printing techniques for graphene and graphene/polymer composites are addressed, including extrusion methods (direct ink writing and fused deposition modeling), photopolymerization strategies (stereolithography and digital light processing) and powder-based techniques. Multifunctional applications in energy storage, physical sensor, stretchable conductor, electromagnetic interference shielding and wave absorption, as well as bio-applications are highlighted. Despite significant advancements in 3D printed graphene and its polymer composites, innovative studies are still necessary to fully unlock their inherent capabilities.

Selective Laser Sintering of Polydimethylsiloxane Composites

Conductive silicone elastomer carbon nanotubes (CNTs) composites possess potential applications in a variety of fields, including electronic skin, wearable electronics, and human motion detection. Based on a novel self-made covalent adaptable network (CANs) of polydimethylsiloxane (PDMS) containg dynamic steric-hindrance pyrazole urea bond (PDMS-CANs), CNTs wrapped PDMS-CANs (CNTs@PDMS-CANs) powders were prepared by a liquid phase adsorption and deposition, and were successfully used for selective laser sintering (SLS) three-dimensional printing. SLS-printed PDMS-CANs/CNTs nanocomposites possess high electrical conductivity and low percolation threshold as SLS is one kind of quasi-static processing, which leads to the formation of conductive segregated CNTs network by using the PDMS powders with special CNTs wrapped structure. The introduction of dynamic pyrazole urea bond endows the materials self-healing capability under electrothermal and photothermal stimulus. In addition, due to the resistance difference of the damaged and intact areas, crack diagnosing can be realized by infrared thermograph under electricity. In an application demonstration in strain sensor, the composite exhibits a regular cyclic electrical resistance change at cyclic compression and bending, indicating a relative high reliability.

Thermal Conductivity and Mechanical Properties of Polymer Composites with Hexagonal Boron Nitride-A Comparison of Three Processing Methods: Injection Moulding, Powder Bed Fusion and Casting

Materials providing heat dissipation and electrical insulation are required for many electronic and medical devices. Polymer composites with hexagonal boron nitride (hBN) may fulfil such requirements. The focus of this study is to compare composites with hBN fabricated by injection moulding (IM), powder bed fusion (PBF) and casting. The specimens were characterised by measuring thermal conductivity, tensile properties, hardness and hBN particle orientation. A thermoplastic polyurethane (TPU) was selected as the matrix for IM and PBF, and an epoxy was the matrix for casting. The maximum filler weight fractions were 65%, 55% and 40% for IM, casting and PBF, respectively. The highest thermal conductivity (2.1 W/m∙K) was measured for an IM specimen with 65 wt% hBN. However, cast specimens had the highest thermal conductivity for a given hBN fraction. The orientation of hBN platelets in the specimens was characterised by X-ray diffraction and compared with numerical simulations. The measured thermal conductivities were discussed by comparing them with four models from the literature (the effective medium approximation model, the Ordóñez-Miranda model, the Sun model, and the Lewis-Nielsen model). These models predicted quite different thermal conductivities vs. filler fraction. Adding hBN increased the hardness and tensile modulus, and the tensile strength at high hBN fractions. The strength had a minimum as the function of filler fraction, while the strain at break decreased. These trends can be explained by two mechanisms which occur when adding hBN: reinforcement and embrittlement.

Advances in the Physico-Chemical, Antimicrobial and Angiogenic Properties of Graphene-Oxide/Cellulose Nanocomposites for Wound Healing

Graphene oxide (GO) and its reduced form (rGO) have recently attracted a fascinating interest due to their physico-chemical properties, which have opened up new and interesting opportunities in a wide range of biomedical applications, such as wound healing. It is worth noting that GO and rGO may offer a convenient access to its ready dispersion within various polymeric matrices (such as cellulose and its derivative forms), owing to their large surface area, based on a carbon skeleton with many functional groups (i.e., hydroxyl, carboxyl, epoxy bridge, and carbonyl moieties). This results in new synergic properties due to the presence of both components (GO or rGO and polymers), acting at different length-scales. Furthermore, they have shown efficient antimicrobial and angiogenic properties, mostly related to the intracellular formation of reactive oxygen species (ROS), which are advantageous in wound care management. For this reason, GO or rGO integration in cellulose-based matrixes have allowed for designing highly advanced multifunctional hybrid nanocomposites with tailored properties. The current review aims to discuss a potential relationship between structural and physico-chemical properties (i.e., size, edge density, surface chemistry, hydrophilicity) of the nanocomposites with antimicrobials and angiogenic mechanisms that synergically influence the wound healing phenomenon, by paying particular attention to recent findings of GO or rGO/cellulose nanocomposites. Accordingly, after providing a general overview of cellulose and its derivatives, the production methods used for GO and rGO synthesis, the mechanisms that guide antimicrobial and angiogenic processes of tissue repair, as well as the most recent and remarkable outcomes on GO/cellulose scaffolds in wound healing applications, will be presented.

Electrical Heating Performance of Graphene/PLA-Based Various Types of Auxetic Patterns and Its Composite Cotton Fabric Manufactured by CFDM 3D Printer

To evaluate the electrical heating performance by auxetic pattern, re-entrant honeycomb (RE), chiral truss (CT), honeycomb (HN), and truss (TR), using graphene/PLA (Polylactic acid) filament, were manufactured by CFDM (conveyor fused deposition modelling) 3D printer. In addition, HN and TR, which was indicated to have an excellent electrical heating property, were selected to verify the feasibility of applying fabric heating elements. The result of morphology was that the number of struts constituting the unit cell and the connected points were TR < HN < CT < RE. It was also influenced by the surface resistivity and electrical heating performance. RE, which has the highest number of struts constituting the unit cell and the relative density, had the highest value of surface resistivity, and the lowest value was found in the opposite TR. In the electrical heating performance of samples, the heat distribution of RE was limited even when the applied voltage was increased. However, HN and TR were diffused throughout the sample. In addition, the surface temperature of RE, CT, HN, and TR was about 72.4 °C, 83.1 °C, 94.9 °C, and 85.9, respectively as applied at 30 V. When the HN and TR were printed on cotton fabric, the surface resistivity of HN/cotton and TR/cotton was about 10³ Ω/sq, which showed conductive material. The results of electrical heating properties indicated that the heat distribution of HN/cotton showed only in the region where power was supplied, but the TR/cotton was gradually expanded and presented stable electric heating properties. When 30 V was applied, the surface temperature of both samples showed more than 80 °C, and the shape was maintained stably due to the high thermal conductivity of the cotton fabric. Therefore, this study ensured that HN and TR show excellent electrical heating performance among four types of auxetic patterns with continuity.

Thermal and Electromagnetic Properties of Polymer Holey Structures Produced by Additive Manufacturing

Multifunctional 3D-printed holey structures made of composite polymers loaded with nanocarbon were designed to serve simultaneously as GHz-radiation absorbing layers and heat conductors. The geometry of the structures was devised to allow heat to be easily transferred through, with special attention paid to thermal conductivity. Numerical calculations and a simple homogenization theory were conducted in parallel to address this property. Different structures have been considered and compared. The electromagnetic shielding effectiveness of the produced holey structures was measured in the microwave range.

Terahertz Optics of Materials with Spatially Harmonically Distributed Refractive Index

The electromagnetic properties of structures with spatially periodic distributed graded refractive index were investigated in the terahertz frequency range. The band structure and electromagnetic response of material with harmonically distributed refractive index were calculated and analyzed. The analytical expressions for frequencies of the first and second bandgap are derived. 3D printed gyroid based architectures were proven to be harmonically graded refractive index structures with designed bandgaps in THz frequency ranges. The transmission coefficient of thermoplastic polyurethane-based samples were experimentally measured in the frequency range 100–500 GHz and compared with theoretical results. Due to losses in the real world produced samples, the predicted response is significantly dumped in the terahertz range and only traces of band gaps are experimentally observed. This funding paves the way toward a new generation of 3D printed THz components for gradient-index optics applications.

On the Synergistic Effect of Multi-Walled Carbon Nanotubes and Graphene Nanoplatelets to Enhance the Functional Properties of SLS 3D-Printed Elastomeric Structures

Elastomer-based porous structures realized by selective laser sintering (SLS) are emerging as a new class of attractive multifunctional materials. Herein, a thermoplastic polyurethane (TPU) powder for SLS was modified by 1 wt.% multi-walled carbon nanotube (MWCNTs) or a mixture of MWCNTs and graphene (GE) nanoparticles (70/30 wt/wt) in order to investigate on both the synergistic effect provided by the two conductive nanostructured carbonaceous fillers and the correlation between formulation, morphology, and final properties of SLS printed porous structures. In detail, porous structures with a porosity ranging from 20% to 60% were designed using Diamond (D) and Gyroid (G) unit cells. Results showed that the carbonaceous fillers improve the thermal stability of the elastomeric matrix. Furthermore, the TPU/1 wt.% MWCNTs-GE-based porous structures exhibit excellent electrical conductivity and mechanical strength. In particular, all porous structures exhibit a robust negative piezoresistive behavior, as demonstrated from the gauge factor (GF) values that reach values of about −13 at 8% strain. Furthermore, the G20 porous structures (20% of porosity) exhibit microwave absorption coefficients ranging from 0.70 to 0.91 in the 12–18 GHz region and close to 1 at THz frequencies (300 GHz–1 THz). Results show that the simultaneous presence of MWCNTs and GE brings a significant enhancement of specific functional properties of the porous structures, which are proposed as potential actuators with relevant electro-magnetic interference (EMI) shielding properties.

Powder-Based 3D Printing for the Fabrication of Device with Micro and Mesoscale Features

Customized manufacturing of a miniaturized device with micro and mesoscale features is a key requirement of mechanical, electrical, electronic and medical devices. Powder-based 3D-printing processes offer a strong candidate for micromanufacturing due to the wide range of materials, fast production and high accuracy. This study presents a comprehensive review of the powder-based three-dimensional (3D)-printing processes and how these processes impact the creation of devices with micro and mesoscale features. This review also focuses on applications of devices with micro and mesoscale size features that are created by powder-based 3D-printing technology.

A Comparative Study of the CMT+P Process on 316L Stainless Steel Additive Manufacturing

Adopting the cold metal transfer plus pulse (CMT + P) process, 316L stainless steel wire was treated with a single channel multi-layer deposition experiment under different linear energy. The microstructures of different regions on the deposited samples were observed by optical microscope and scanning electron microscope, and the element distribution in the structure was analyzed by energy dispersive spectrometer. The mechanical properties and microhardness were measured by tensile test method and microhardness tester, respectively, and the anisotropy of tensile strength in horizontal and vertical directions were calculated. Finally, the fracture morphology of the tensile samples were observed by SEM. Experiment results showed that when the difference between the actual and the optimal wire feeding speed matching the specific welding speed was too large, this led to an unstable deposition process as well as flow and collapse of weld bead metal, thus seriously deteriorating the appearance of the deposition samples. The results from metallographic micrograph showed that rapid heat dissipation of the substrate caused small grains to generate in the bottom region of deposition samples, then gradually grew up to coarse dendrites along the building direction in the middle and top region caused by the continuous heat accumulation during deposition. Tensile test results showed that with the increase of linear energy, the horizontal and vertical tensile strength of the as-deposited samples decreased. In addition, the higher linear energy would deteriorate the microstructure of as-deposited parts, including significantly increasing the tendency of oxidation and material stripping. The microhardness values of the bottom, middle and top regions of the samples fluctuated along the centerline of the cross-section, and the values showed a trend of decreasing first and then rising along the building direction. Meanwhile, the yield strength and tensile strength of each specimen showed obvious anisotropy due to unique grain growth morphology. On the whole, the results from this study prove that CMT+P process is a feasible MIG welding additive manufacturing method for 316L stainless steel.

Creation of metasurface from vertically aligned carbon nanotubes as versatile platform for ultra-light THz components

Here a simple and reproducible method for obtaining terahertz metasurfaces formed from multiwall carbon nanotubes (MWCNTs) is presented. The metasurfaces were obtained from a vertically aligned array of MWCNTs using a laser engraving technique followed by polymer covering. The structures under study demonstrate frequency-selective reflection in terahertz range following the Huygens-Fresnel formalism. For a normal incidence of the electromagnetic wave, the model for numerical calculation of backscattering from the metasurfaces was proposed. Lightweight and compact MWCNT-based metasurfaces are capable to replace conventional pyramidal absorbers and could serve as a versatile platform for scalable cost-efficient production of ultra-light electromagnetic components for THz applications.

Performance Assessment of a Three-Dimensional Printed Porous Media Produced by Selective Laser Melting Technology for the Optimization of Loop Heat Pipe Wicks

The primary wick in a loop heat pipe device is a key component that is central to the operation of the device. Both high permeability and capillary pumping capacity, two properties highly dependent on wick structure, are strongly desirable for a satisfactory thermal performance. In this paper, selective laser melting (SLM), a three-dimensional (3D) printing technology, is used to create a primary wick for an 80 W heat transfer application. The permeability and capillarity values of this wick, experimentally measured, are compared with those built with the most widely used technologies nowadays, such as powder sintering and meshes. In this study, the SLM scaffold is shown to satisfy the minimum values required by the application in terms of capillarity and permeability: 0.031 mm/s and 4 × 10−12 m2, respectively. Our comparative study revealed that the wick produced with the SLM technology presented higher values of permeability, by two orders of magnitude, and slightly higher capillary figures than those corresponding to powder sintering for such application. However, it had capillary values well below those of a stainless-steel mesh. The hydraulic behavior of the SLM wick was better than that of the sintered copper powder, because it not only met the above-mentioned specifications, but it also improved its performance.