Micropatterning of Metal Nanoparticle Ink by Laser-Induced Thermocapillary Flow

Nanoparticle Assembly: From Self-Organization to Controlled Micropatterning for Enhanced Functionalities

Nanoparticles form long-range micropatterns via self-assembly or directed self-assembly with superior mechanical, electrical, optical, magnetic, chemical, and other functional properties for broad applications, such as structural supports, thermal exchangers, optoelectronics, microelectronics, and robotics. The precisely defined particle assembly at the nanoscale with simultaneously scalable patterning at the microscale is indispensable for enabling functionality and improving the performance of devices. This article provides a comprehensive review of nanoparticle assembly formed primarily via the balance of forces at the nanoscale (e.g., van der Waals, colloidal, capillary, convection, and chemical forces) and nanoparticle-template interactions (e.g., physical confinement, chemical functionalization, additive layer-upon-layer). The review commences with a general overview of nanoparticle self-assembly, with the state-of-the-art literature review and motivation. It subsequently reviews the recent progress in nanoparticle assembly without the presence of surface templates. Manufacturing techniques for surface template fabrication and their influence on nanoparticle assembly efficiency and effectiveness are then explored. The primary focus is the spatial organization and orientational preference of nanoparticles on non-templated and pre-templated surfaces in a controlled manner. Moreover, the article discusses broad applications of micropatterned surfaces, encompassing various fields. Finally, the review concludes with a summary of manufacturing methods, their limitations, and future trends in nanoparticle assembly.

Direct Writing of Functional Layer by Selective Laser Sintering of Nanoparticles for Emerging Applications: A Review

Selective laser sintering of nanoparticles enables the direct and rapid formation of a functional layer even on heat-sensitive flexible and stretchable substrates, and is rising as a pioneering fabrication technology for future-oriented applications. To date, laser sintering has been successfully applied to various target nanomaterials including a wide range of metal and metal-oxide nanoparticles, and extensive investigation of relevant experimental schemes have not only reduced the minimum feature size but also have further expanded the scalability of the process. In the beginning, the selective laser sintering process was regarded as an alternative method to conventional manufacturing processes, but recent studies have shown that the unique characteristics of the laser-sintered layer may improve device performance or even enable novel functionalities which were not achievable using conventional fabrication techniques. In this regard, we summarize the current developmental status of the selective laser sintering technique for nanoparticles, affording special attention to recent emerging applications that adopt the laser sintering scheme.

One-Step Template-Free Laser Patterning of Metal Microhoneycomb Structures

Metal microhoneycomb structures have received considerable attention as a type of interaction-efficient functional devices owing to their unique morphology and material properties. Microhoneycomb structures are mainly fabricated using the well-known breath-figure method. However, additional post-treatments are required to produce a metal structure because it is a polymer-based process, and this necessitates expensive, complex, and multi-step fabrication processes. Therefore, a simple, low-cost metal honeycomb fabrication process is necessary. In this paper, the laser patterning of an organometallic solution to produce silver microhoneycomb (Ag microhoneycomb) structures is proposed. Various phenomena such as rapid organic evaporation, silver nanoparticle solidification, and material reorganization from Marangoni flow are found to enable patterning-induced microhoneycomb formation. Parametric studies demonstrate that the pore size can be easily controlled through simple laser parameter changes. In addition, cyclic voltammetry and electrochemical impedance spectroscopy studies confirm the potential electrochemical applications of the Ag microhoneycomb structures based on the variation of electrochemical redox behavior depending on the pore size. Owing to the excellent advantages of one-step laser patterning without any templates, the proposed process will likely promote the practical use of the metal microhoneycomb structures.

A Transformative Gold Patterning through Selective Laser Refining of Cyanide

Gold is an essential noble metal for electronics, and its application area is increasing continuously through the introduction of gold nanoparticle ink that enables rapid prototyping and direct writing of gold electrodes on versatile substrates at a low temperature. However, the synthesis of gold nanoparticles has certain limitations involving high cost, long synthesis time, large waste of material, and frequent use of chemicals. In this study, we suggest simultaneous laser refining of gold cyanide and selective fabrication of gold electrodes directly on the substrate without a separate synthesis step. Gold cyanide is commonly the first product of gold from the primitive ore, and the gold can be extracted directly from the rapid photothermal decomposition of gold cyanide by the laser. It was confirmed that laser-induced thermocapillary force plays an important role in creating the continuous gold patterns by aligning the refined gold. The resultant gold electrodes exhibited a low resistivity analogous to the conventional direct writing method using nanoparticles, and the facile repair process of a damaged electrode was demonstrated as the proof-of-concept. The proposed transformative approach for gold patterning, distinguished from the previous top-down and bottom-up approaches, has the potential to replace the well-known techniques and provide a new branch of electrode manufacturing scheme.

Current Strategies for Noble Metal Nanoparticle Synthesis

Noble metals have played an integral part in human history for centuries; however, their integration with recent advances in nanotechnology and material sciences have provided new research opportunities in both academia and industry, which has resulted in a new array of advanced applications, including medical ones. Noble metal nanoparticles (NMNPs) have been of great importance in the field of biomedicine over the past few decades due to their importance in personalized healthcare and diagnostics. In particular, platinum, gold and silver nanoparticles have achieved the most dominant spot in the list, thanks to a very diverse range of industrial applications, including biomedical ones such as antimicrobial and antiviral agents, diagnostics, drug carriers and imaging probes. In particular, their superior resistance to extreme conditions of corrosion and oxidation is highly appreciated. Notably, in the past two decades there has been a tremendous advancement in the development of new strategies of more cost-effective and robust NMNP synthesis methods that provide materials with highly tunable physicochemical, optical and thermal properties, and biochemical functionalities. As a result, new advanced hybrid NMNPs with polymer, graphene, carbon nanotubes, quantum dots and core-shell systems have been developed with even more enhanced physicochemical characteristics that has led to exceptional diagnostic and therapeutic applications. In this review, we aim to summarize current advances in the synthesis of NMNPs (Au, Ag and Pt).

Human Mesenchymal Stem Cell Derived Exosomes Enhance Cell-Free Bone Regeneration by Altering Their miRNAs Profiles

Implantation of stem cells for tissue regeneration faces significant challenges such as immune rejection and teratoma formation. Cell-free tissue regeneration thus has a potential to avoid these problems. Stem cell derived exosomes do not cause immune rejection or generate malignant tumors. Here, exosomes that can induce osteogenic differentiation of human mesenchymal stem cells (hMSCs) are identified and used to decorate 3D-printed titanium alloy scaffolds to achieve cell-free bone regeneration. Specifically, the exosomes secreted by hMSCs osteogenically pre-differentiated for different times are used to induce the osteogenesis of hMSCs. It is discovered that pre-differentiation for 10 and 15 days leads to the production of osteogenic exosomes. The purified exosomes are then loaded into the scaffolds. It is found that the cell-free exosome-coated scaffolds regenerate bone tissue as efficiently as hMSC-seeded exosome-free scaffolds within 12 weeks. RNA-sequencing suggests that the osteogenic exosomes induce the osteogenic differentiation by using their cargos, including upregulated osteogenic miRNAs (Hsa-miR-146a-5p, Hsa-miR-503-5p, Hsa-miR-483-3p, and Hsa-miR-129-5p) or downregulated anti-osteogenic miRNAs (Hsa-miR-32-5p, Hsa-miR-133a-3p, and Hsa-miR-204-5p), to activate the PI3K/Akt and MAPK signaling pathways. Consequently, identification of osteogenic exosomes secreted by pre-differentiated stem cells and the use of them to replace stem cells represent a novel cell-free bone regeneration strategy.

Exploring Electrochemical Extrusion of Wires from Liquid Metals

Metal melt extrusion in gaseous or vacuum environments is a classical approach for forming wires. However, such extrusions have not been investigated in ionic solutions. Here, we use liquid metal (LM) gallium (Ga) and its eutectic alloy with indium (EGaIn) to explore the possibility of electrochemical extrusion of wires and study the tuning of the self-liming oxide layers as the coating for these wires formed during the process. By controlling the surface tension of the LM immersed in an electrolyte, and through the electrocapillary effect, we enable the extrusion of LM wires. The surface morphologies of LM wires and the thickness of the oxide layers are investigated when Ga and EGaIn are processed in neutral and basic electrolytes using various voltages. Taking advantage of the LM oxides, we show that LM wires offer tunable surface oxide thickness and composition using the electrochemical system and investigate the related working mechanisms. The wires are formed into patterns using an automated stage and show a self-healing capability. This work presents an unconventional method for electrochemical fabrication of LM wires, offering prospects for further research and industrial scale-up.

Continuous-Wave Laser-Induced Transfer of Metal Nanoparticles to Arbitrary Polymer Substrates

Laser-induced forward transfer (LIFT) and selective laser sintering (SLS) are two distinct laser processes that can be applied to metal nanoparticle (NP) ink for the fabrication of a conductive layer on various substrates. A pulsed laser and a continuous-wave (CW) laser are utilized respectively in the conventional LIFT and SLS processes; however, in this study, CW laser-induced transfer of the metal NP is proposed to achieve simultaneous sintering and transfer of the metal NP to a wide range of polymer substrates. At the optimum laser parameters, it was shown that a high-quality uniform metal conductor was created on the acceptor substrate while the metal NP was sharply detached from the donor substrate, and we anticipate that such an asymmetric transfer phenomenon is related to the difference in the adhesion strengths. The resultant metal electrode exhibits a low resistivity that is comparable to its bulk counterpart, together with strong adhesion to the target polymer substrate. The versatility of the proposed process in terms of the target substrate and applicable metal NPs brightens its prospects as a facile manufacturing scheme for flexible electronics.

Shear-Assisted Laser Transfer of Metal Nanoparticle Ink to an Elastomer Substrate

Selective laser sintering of metal nanoparticle ink is an attractive technology for the creation of metal layers at the microscale without any vacuum deposition process, yet its application to elastomer substrates has remained a highly challenging task. To address this issue, we introduced the shear-assisted laser transfer of metal nanoparticle ink by utilizing the difference in thermal expansion coefficients between the elastomer and the target metal electrode. The laser was focused and scanned across the absorbing metal nanoparticle ink layer that was in conformal contact with the elastomer with a high thermal expansion coefficient. The resultant shear stress at the interface assists the selective transfer of the sintered metal nanoparticle layer. We expect that the proposed method can be a competent fabrication route for a transparent conductor on elastomer substrates.

Research and Development of a 3D Jet Printer for High-Viscosity Molten Liquids

Micro-droplet jetting manufacture is a new 3D printing technology developed in recent years. Presently, this new technology mainly aims at ejecting a low-viscosity medium. Therefore, a device for ejecting high-viscosity molten liquid is designed by analyzing the injection principle of high-viscosity molten liquid. Initially, the cooling mechanism is designed to overcome the defect that the piezoelectric stacks cannot operate in high-temperature conditions. Thereafter, the mathematical model of the liquid velocity in the nozzle is derived, and the factors influencing injection are verified by Fluent. Subsequently, a prototype of the jet printer is fabricated, and the needle velocity is tested by the laser micrometer; the relationship between voltage difference and the needle velocity is also obtained. The experimental results matched the theoretical model well, showing that the voltage difference, needle radius, nozzle diameter, and taper angle are closely related to the injection performance of the 3D jet printer. By using a needle with a radius of 0.4 mm, a nozzle with a diameter of 50 μm, a taper angle of 90°, a supply pressure of 0.05 Mpa, and a voltage difference of 98 V, a molten liquid with a viscosity of 8000 cps can be ejected with a minimum average diameter of 275 μm, and the variation of the droplet diameter is within ±3.8%.