Directed Assembly of Particles for Additive Manufacturing of Particle-Polymer Composites

Active control of equilibrium, near-equilibrium, and far-from-equilibrium colloidal systems

The development of top-down active control over bottom-up colloidal assembly processes has the potential to produce materials, surfaces, and objects with applications in a wide range of fields spanning from computing to materials science to biomedical engineering. In this review, we summarize recent progress in the field using a taxonomy based on how active control is used to guide assembly. We find there are three distinct scenarios: (1) navigating kinetic pathways to reach a desirable equilibrium state, (2) the creation of a desirable metastable, kinetically trapped, or kinetically arrested state, and (3) the creation of a desirable far-from-equilibrium state through continuous energy input. We review seminal works within this framework, provide a summary of important application areas, and present a brief introduction to the fundamental concepts of control theory that are necessary for the soft materials community to understand this literature. In addition, we outline current and potential future applications of actively-controlled colloidal systems, and we highlight important open questions and future directions.

Extrusion-Based 3D Printing of Stretchable Electronic Coating for Condition Monitoring of Suction Cups

Suction cups (SCs) are used extensively by the industrial sector, particularly for a wide variety of automated material-handling applications. To enhance productivity and reduce maintenance costs, an online supervision system is essential to check the status of SCs. This paper thus proposes an innovative method for condition monitoring of SCs coated with printed electronics whose electrical resistance is supposed to be correlated with the mechanical strain. A simulation model is first examined to observe the deformation of SCs under vacuum compression, which is needed for the development of sensor coating thanks to the 3D printing process. The proposed design involves three circle-shaped sensors, two for the top and bottom bellows (whose mechanical strains are revealed to be the most significant), and one for the lip (small strain, but important stress that might provoke wear and tear in the long term). For the sake of simplicity, practical measurement is performed on 2D samples coated with two different conductive inks subjected to unidirectional tensile loading. Graphical representations together with analytical models of both linear and nonlinear piezoresistive responses allows for the characterization of the inks' behavior under several conditions of displacement and speed inputs. After a comparison of the two inks, the most appropriate is selected as a consequence of its excellent adhesion and stretchability, which are essential criteria to meet the target field. Room temperature extrusion-based 3D printing is then investigated using a motorized 3D Hyrel printer with a syringe-extrusion modular system. Design optimization is finally carried out to enhance the surface detection of sensitive elements while minimizing the effect of electrodes. Although several issues still need to be further considered to match specifications imposed by our industrial partner, the achievement of this work is meaningful and could pave the way for a new generation of SCs integrated with smart sensing devices. The 3D printing of conductive ink directly on the cup's curving surface is a true challenge, which has been demonstrated, for the first time, to be technically feasible throughout the additive manufacturing (AM) process.

Directional Migration and Distribution of Magnetic Microparticles in Polypropylene-Matrix Magnetic Composites Molded by an Injection Molding Assisted by External Magnetic Field

Surface-functionalized polymer composites with spherical particles as fillers offer great qualities and have been widely employed in applications of sensors, pharmaceutical industries, anti-icing, and flexible electromagnetic interference shielding. The directional migration and dispersion theory of magnetic microparticles in polypropylene (PP)-matrix magnetic composites must be studied to better acquire the functional surface with remarkable features. In this work, a novel simulation model based on multi-physical field coupling was suggested to analyze the directed migration and distribution of magnetic ferroferric oxide (Fe₃O₄) particles in injection molding assisted by an external magnetic field using COMSOL Multiphysics^® software. To accurately introduce rheological phenomena of polymer melt into the simulation model, the Carreau model was used. Particle size, magnetic field intensity, melt viscosity, and other parameters impacting particle directional motion were discussed in depth. The directional distribution of particles in the simulation model was properly assessed and confirmed by experiment results. This model provides theoretical support for the control, optimization, and investigation of the injection-molding process control of surface-functionalized polymer composites.

Coil Formation of a Silicone String Using UV-Ozone Treatment

Microcoils are used in various mechanical devices. However, existing methods for producing microcoils from polymers often require expensive equipment. In this study, microcoils were prepared using a cost-effective and simple method. The material used was silicone, which is a biocompatible polymeric material. Silicone was solidified inside glass capillaries to form thin, straight strings with a diameter of 140 μm. The string was then transformed to a coil shape by oxidation using UV-ozone treatment while it was prestretched and pretwisted. The resilience force from the prestretching and pretwisting forces caused the string to bend and twist, respectively. As a result of the combination of these deformation modes, a coil was formed. As an application of the coils, an actuator was prepared, which repeatedly transforms between straight and coiled shapes. The actuation was caused by the swelling/deswelling of silicone with hexane. A large strain of 54% was obtained.

Acoustics-Actuated Microrobots

Microrobots can operate in tiny areas that traditional bulk robots cannot reach. The combination of acoustic actuation with microrobots extensively expands the application areas of microrobots due to their desirable miniaturization, flexibility, and biocompatibility features. Herein, an overview of the research and development of acoustics-actuated microrobots is provided. We first introduce the currently established manufacturing methods (3D printing and photolithography). Then, according to their different working principles, we divide acoustics-actuated microrobots into three categories including bubble propulsion, sharp-edge propulsion, and in-situ microrotor. Next, we summarize their established applications from targeted drug delivery to microfluidics operation to microsurgery. Finally, we illustrate current challenges and future perspectives to guide research in this field. This work not only gives a comprehensive overview of the latest technology of acoustics-actuated microrobots, but also provides an in-depth understanding of acoustic actuation for inspiring the next generation of advanced robotic devices.