Custom-Designed Glassy Carbon Tips for Atomic Force Microscopy

Opportunities at the Intersection of 3D Printed Polymers and Pyrolysis for the Microfabrication of Carbon-Based Energy Materials

In an era marked by a growing demand for sustainable and high-performance materials, the convergence of additive manufacturing (AM), also known as 3D printing, and the thermal treatment, or pyrolysis, of polymers to form high surface area hierarchically structured carbon materials stands poised to catalyze transformative advancements across a spectrum of electrification and energy storage applications. Designing 3D printed polymers using low-cost resins specifically for conversion to high performance carbon structures via post-printing thermal treatments overcomes the challenges of 3D printing pure carbon directly due to the inability of pure carbon to be polymerized, melted, or sintered under ambient conditions. In this perspective, we outline the current state of AM methods that have been used in combination with pyrolysis to generate 3D carbon structures and highlight promising systems to explore further. As part of this endeavor, we discuss the effects of 3D printed polymer chemistry composition, additives, and pyrolysis conditions on resulting 3D pyrolytic carbon properties. Furthermore, we demonstrate the viability of combining continuous liquid interface production (CLIP) vat photopolymerization with pyrolysis as a promising avenue for producing 3D pyrolytic carbon lattice structures with 15 μm feature resolution, paving way for 3D carbon-based sustainable energy applications.

Pick and place process for uniform shrinking of 3D printed micro- and nano-architected materials

Two-photon polymerization lithography is promising for producing three-dimensional structures with user-defined micro- and nanoscale features. Additionally, shrinkage by thermolysis can readily shorten the lattice constant of three-dimensional photonic crystals and enhance their resolution and mechanical properties; however, this technique suffers from non-uniform shrinkage owing to substrate pinning during heating. Here, we develop a simple method using poly(vinyl alcohol)-assisted uniform shrinking of three-dimensional printed structures. Microscopic three-dimensional printed objects are picked and placed onto a receiving substrate, followed by heating to induce shrinkage. We show the successful uniform heat-shrinking of three-dimensional prints with various shapes and sizes, without sacrificial support structures, and observe that the surface properties of the receiving substrate are important factors for uniform shrinking. Moreover, we print a three-dimensional mascot model that is then uniformly shrunk, producing vivid colors from colorless woodpile photonic crystals. The proposed method has significant potential for application in mechanics, optics, and photonics.

Laser-Carbonization - A Powerful Tool for Micro-Fabrication of Patterned Electronic Carbons

Fabricating electronic devices from natural, renewable resources is a common goal in engineering and materials science. In this regard, carbon is of special significance due to its biocompatibility combined with electrical conductivity and electrochemical stability. In microelectronics, however, carbon's device application is often inhibited by tedious and expensive preparation processes and a lack of control over processing and material parameters. Laser-assisted carbonization is emerging as a tool for the precise and selective synthesis of functional carbon-based materials for flexible device applications. In contrast to conventional carbonization via in-furnace pyrolysis, laser-carbonization is induced photo-thermally and occurs on the time-scale of milliseconds. By careful selection of the precursors and process parameters, the properties of this so-called laser-patterned carbon (LP-C) such as porosity, surface polarity, functional groups, degree of graphitization, charge-carrier structure, etc. can be tuned. In this critical review, a common perspective is generated on laser-carbonization in the context of general carbonization strategies, fundamentals of laser-induced materials processing, and flexible electronic applications, like electrodes for sensors, electrocatalysts, energy storage, or antennas. An attempt is made to have equal emphasis on material processing and application aspects such that this emerging technology can be optimally positioned in the broader context of carbon-based microfabrication.

Carbon-based neural electrodes: promises and challenges

Neural electrodes are primary functional elements of neuroelectronic devices designed to record neural activity based on electrochemical signals. These electrodes may also be utilized for electrically stimulating the neural cells, such that their response can be simultaneously recorded. In addition to being medically safe, the electrode material should be electrically conductive and electrochemically stable under harsh biological environments. Mechanical flexibility and conformability, resistance to crack formation and compatibility with common microfabrication techniques are equally desirable properties. Traditionally, (noble) metals have been the preferred for neural electrode applications due to their proven biosafety and a relatively high electrical conductivity. Carbon is a recent addition to this list, which is far superior in terms of its electrochemical stability and corrosion resistance. Carbon has also enabled 3D electrode fabrication as opposed to the thin-film based 2D structures. One of carbon's peculiar aspects is its availability in a wide range of allotropes with specialized properties that render it highly versatile. These variations, however, also make it difficult to understand carbon itself as a unique material, and thus, each allotrope is often regarded independently. Some carbon types have already shown promising results in bioelectronic medicine, while many others remain potential candidates. In this topical review, we first provide a broad overview of the neuroelectronic devices and the basic requirements of an electrode material. We subsequently discuss the carbon family of materials and their properties that are useful in neural applications. Examples of devices fabricated using bulk and nano carbon materials are reviewed and critically compared. We then summarize the challenges, future prospects and next-generation carbon technology that can be helpful in the field of neural sciences. The article aims at providing a common platform to neuroscientists, electrochemists, biologists, microsystems engineers and carbon scientists to enable active and comprehensive efforts directed towards carbon-based neuroelectronic device fabrication.

Lipid nanotubes as an organic template for the fabrication of carbon nanostructures by pyrolysis

We demonstrate the fabrication of carbon nanoribbons with a width of 40 nm based on fixation and pyrolysis of an organic template, lipid nanotubes. To our best knowledge, this is the smallest feature size achieved by pyrolysis of surface-patterned organic templates. Such a pyrolytic carbon nanostructure can be used for electronics and sensing applications in future.

Structural color three-dimensional printing by shrinking photonic crystals

The coloration of some butterflies, Pachyrhynchus weevils, and many chameleons are notable examples of natural organisms employing photonic crystals to produce colorful patterns. Despite advances in nanotechnology, we still lack the ability to print arbitrary colors and shapes in all three dimensions at this microscopic length scale. Here, we introduce a heat-shrinking method to produce 3D-printed photonic crystals with a 5x reduction in lattice constants, achieving sub-100-nm features with a full range of colors. With these lattice structures as 3D color volumetric elements, we printed 3D microscopic scale objects, including the first multi-color microscopic model of the Eiffel Tower measuring only 39 µm tall with a color pixel size of 1.45 µm. The technology to print 3D structures in color at the microscopic scale promises the direct patterning and integration of spectrally selective devices, such as photonic crystal-based color filters, onto free-form optical elements and curved surfaces.

Pyrolysis-induced shrinking of three-dimensional structures fabricated by two-photon polymerization: experiment and theoretical model

The introduction of two-photon polymerization (TPP) into the area of Carbon Micro Electromechanical Systems (C-MEMS) has enabled the fabrication of three-dimensional glassy carbon nanostructures with geometries previously unattainable through conventional UV lithography. Pyrolysis of TPP structures conveys a characteristic reduction of feature size-one that should be properly estimated in order to produce carbon microdevices with accuracy. In this work, we studied the volumetric shrinkage of TPP-derived microwires upon pyrolysis at 900 °C. Through this process, photoresist microwires thermally decompose and shrink by as much as 75%, resulting in glassy carbon nanowires with linewidths between 300 and 550 nm. Even after the thermal decomposition induced by the pyrolysis step, the linewidth of the carbon nanowires was found to be dependent on the TPP exposure parameters. We have also found that the thermal stress induced during the pyrolysis step not only results in axial elongation of the nanowires, but also in buckling in the case of slender carbon nanowires (for aspect ratios greater than 30). Furthermore, we show that the calculated residual mass fraction that remains after pyrolysis depends on the characteristic dimensions of the photoresist microwires, a trend that is consistent with several works found in the literature. This phenomenon is explained through a semi-empirical model that estimates the feature size of the carbon structures, serving as a simple guideline for shrinkage evaluation in other designs.

Evolution of Glassy Carbon Microstructure: In Situ Transmission Electron Microscopy of the Pyrolysis Process

Glassy carbon is a graphene-rich form of elemental carbon obtained from pyrolysis of polymers, which is composed of three-dimensionally arranged, curved graphene fragments alongside fractions of disordered carbon and voids. Pyrolysis encompasses gradual heating of polymers at ≥ 900 °C under inert atmosphere, followed by cooling to room temperature. Here we report on an experimental method to perform in situ high-resolution transmission electron microscopy (HR-TEM) for the direct visualization of microstructural evolution in a pyrolyzing polymer in the 500-1200 °C temperature range. The results are compared with the existing microstructural models of glassy carbon. Reported experiments are performed at 80 kV acceleration voltage using MEMS-based heating chips as sample substrates to minimize any undesired beam-damage or sample preparation induced transformations. The outcome suggests that the geometry, expansion and atomic arrangement within the resulting graphene fragments constantly change, and that the intermediate structures provide important cues on the evolution of glassy carbon. A complete understanding of the pyrolysis process will allow for a general process tuning specific to the precursor polymer for obtaining glassy carbon with pre-defined properties.

Glassy Carbon: A Promising Material for Micro- and Nanomanufacturing

When certain polymers are heat-treated beyond their degradation temperature in the absence of oxygen, they pass through a semi-solid phase, followed by the loss of heteroatoms and the formation of a solid carbon material composed of a three-dimensional graphenic network, known as glassy (or glass-like) carbon. The thermochemical decomposition of polymers, or generally of any organic material, is defined as pyrolysis. Glassy carbon is used in various large-scale industrial applications and has proven its versatility in miniaturized devices. In this article, micro and nano-scale glassy carbon devices manufactured by (i) pyrolysis of specialized pre-patterned polymers and (ii) direct machining or etching of glassy carbon, with their respective applications, are reviewed. The prospects of the use of glassy carbon in the next-generation devices based on the material's history and development, distinct features compared to other elemental carbon forms, and some large-scale processes that paved the way to the state-of-the-art, are evaluated. Selected support techniques such as the methods used for surface modification, and major characterization tools are briefly discussed. Barring historical aspects, this review mainly covers the advances in glassy carbon device research from the last five years (2013⁻2018). The goal is to provide a common platform to carbon material scientists, micro/nanomanufacturing experts, and microsystem engineers to stimulate glassy carbon device research.

Design and Realization of 3D Printed AFM Probes

Atomic force microscope (AFM) probes and AFM imaging by extension are the product of exceptionally refined silicon micromachining, but are also restricted by the limitations of these fabrication techniques. Here, the nanoscale additive manufacturing technique direct laser writing is explored as a method to print monolithic cantilevered probes for AFM. Not only are 3D printed probes found to function effectively for AFM, but they also confer several advantages, most notably the ability to image in intermittent contact mode with a bandwidth approximately ten times larger than analogous silicon probes. In addition, the arbitrary structural control afforded by 3D printing is found to enable programming the modal structure of the probe, a capability that can be useful in the context of resonantly amplifying nonlinear tip-sample interactions. Collectively, these results show that 3D printed probes complement those produced using conventional silicon micromachining and open the door to new imaging techniques.

3D Carbon Scaffolds for Neural Stem Cell Culture and Magnetic Resonance Imaging

3D glassy carbon structures with percolated macropores are obtained by pyrolysis of chemically synthesized cryogels featuring tunable porosity. These batch-fabricated structures are used as scaffolds for culturing neural stem cells (NSCs) and are characterized by magnetic resonance imaging (MRI). With the aid of MRI, the successful cultivation of NSCs on a glassy carbon surface and the precise 3D locations of these cell clusters within the opaque scaffold are demonstrated. MRI also yields pore morphology and porosity analyses, pre- and post-pyrolysis. This integrated approach yields a complete 3D dataset of the NSC network, which enables the visual inspection of the morphological details of individual cell clusters without disturbing them or destroying the scaffold. Reported experimental methodology is expected to have an impact on studies designed to understand the mechanism of neurodegenerative disease (ND) development, and can serve as a protocol for the culture of various other types of cells that display compatibility with glassy carbon surfaces.