Droplet-Pen Writing of Ultra-Uniform Graphene Pattern for Multi-Spectral Applications

Artificial optical patterns bring wide benefits in applications like structural color display, photonic camouflage, and electromagnetic cloak. Their scalable coating on large-scale objects will greatly enrich the multimodal-interactive society. Here, a droplet-pen writing (DPW) method to directly write multi-spectral patterns of thin-film graphene is reported. By amphiphilicity regulations of 2D graphene nanosheets, ultra-uniform and ultrathin films can spontaneously form on droplet caps and pave to the substrate, thus inducing optical interference. This allows the on-surface patterning by pen writing of droplets. Specifically, drop-on-demand thin films are achieved with millimeter lateral size and uniformity up to 97% in subwavelength thickness (<100 nm), corresponding to an aspect ratio of over 30 000. The pixelated thin-film patterns of disks and lines in an 8-inch wafer scale are demonstrated, which enable low-emittance structural color paintings. Furthermore, the applications of these patterns for dual-band camouflage and infrared-to-visible encryption are investigated. This study highlights the potential of 2D material self-assembly in the large-scale preparation and multi-spectral application of thin film-based optical patterns.

Graphene removal by water-assisted focused electron-beam-induced etching - unveiling the dose and dwell time impact on the etch profile and topographical changes in SiO2 substrates

Graphene is one of the most extensively studied 2D materials, exhibiting extraordinary mechanical and electronic properties. Although many years have passed since its discovery, manipulating single graphene layers is still challenging using standard resist-based lithography techniques. Recently, it has been shown that it is possible to etch graphene directly in water-assisted processes using the so-called focused electron-beam-induced etching (FEBIE), with a spatial resolution of ten nanometers. Nanopatterning graphene with such a method in one single step and without using a physical mask or resist is a very appealing approach. During the process, on top of graphene nanopatterning, we have found significant morphological changes induced in the SiO2 substrate even at low electron dose values (<8 nC/μm2). We demonstrate that graphene etching and topographical changes in SiO2 substrates can be controlled via electron beam parameters such as dwell time and dose.

Printable Liquid Metal Foams That Grow When Watered

Pastes and "foams" containing liquid metal (LM) as the continuous phase (liquid metal foams, LMFs) exhibit metallic properties while displaying paste or putty-like rheological behavior. These properties enable LMFs to be patterned into soft and stretchable electrical and thermal conductors through processes conducted at room temperature, such as printing. The simplest LMFs, featured in this work, are made by stirring LM in air, thereby entraining oxide-lined air "pockets" into the LM. Here, it is reported that mixing small amounts of water (as low as 1 wt%) into such LMFs gives rise to significant foaming by harnessing known reactions that evolve hydrogen and produce oxides. The resulting structures can be ≈4-5× their original volume and possess a fascinating combination of attributes: porosity, electrical conductivity, and responsiveness to environmental conditions. This expansion can be utilized for a type of 4D printing in which patterned conductors "grow," fill cavities, and change shape and density with respect to time. Excessive exposure to water in the long term ultimately consumes the metal in the LMF. However, when exposure to water is controlled, the metallic properties of porous LMFs can be preserved.

Cleanroom-Free Direct Laser Micropatterning of Polymers for Organic Electrochemical Transistors in Logic Circuits and Glucose Biosensors

Organic electrochemical transistors (OECTs) are promising devices for bioelectronics, such as biosensors. However, current cleanroom-based microfabrication of OECTs hinders fast prototyping and widespread adoption of this technology for low-volume, low-cost applications. To address this limitation, a versatile and scalable approach for ultrafast laser microfabrication of OECTs is herein reported, where a femtosecond laser to pattern insulating polymers (such as parylene C or polyimide) is first used, exposing the underlying metal electrodes serving as transistor terminals (source, drain, or gate). After the first patterning step, conducting polymers, such as poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS), or semiconducting polymers, are spin-coated on the device surface. Another femtosecond laser patterning step subsequently defines the active polymer area contributing to the OECT performance by disconnecting the channel and gate from the surrounding spin-coated film. The effective OECT width can be defined with high resolution (down to 2 µm) in less than a second of exposure. Micropatterning the OECT channel area significantly improved the transistor switching performance in the case of PEDOT:PSS-based transistors, speeding up the devices by two orders of magnitude. The utility of this OECT manufacturing approach is demonstrated by fabricating complementary logic (inverters) and glucose biosensors, thereby showing its potential to accelerate OECT research.

Scalable Printing of Metal Nanostructures through Superluminescent Light Projection

Direct printing of metallic nanostructures is highly desirable but current techniques cannot achieve nanoscale resolutions or are too expensive and slow. Photoreduction of solvated metal ions into metallic nanoparticles is an attractive strategy because it is faster than deposition-based techniques. However, it is still limited by the resolution versus cost tradeoff because sub-diffraction printing of nanostructures requires high-intensity light from expensive femtosecond lasers. Here, this tradeoff is overcome by leveraging the spatial and temporal coherence properties of low-intensity diode-based superluminescent light. The superluminescent light projection (SLP) technique is presented to rapidly print sub-diffraction nanostructures, as small as 210 nm and at periods as small as 300 nm, with light that is a billion times less intense than femtosecond lasers. Printing of arbitrarily complex 2D nanostructured silver patterns over 30 µm × 80 µm areas in 500 ms time scales is demonstrated. The post-annealed nanostructures exhibit an electrical conductivity up to 1/12th that of bulk silver. SLP is up to 480 times faster and 35 times less expensive than printing with femtosecond lasers. Therefore, it transforms nanoscale metal printing into a scalable format, thereby significantly enhancing the transition of nano-enabled devices from research laboratories into real-world applications.

Substrate Versatile Roller Ball Pen Writing of Nanoporous MoS2 for Energy Storage Devices

Low-cost fabrication of customizable supercapacitors and batteries to power up portable electronic devices is a much-needed step in advancing energy storage devices. The processing methods and techniques involved in developing small-sized entities in complex patterns are expensive, tedious, and time-consuming. Here, we demonstrate the fabrication of customizable electrochemical supercapacitors and batteries by simply employing the universal and conventional paradigm of direct pen writing with hands and evaluating their energy storage performance. The fabrication technique involves the refilling of MoS2 ink into the pen and then scripting of MoS2 nanostructures onto various substrates. The electrode material employed here consists of nanoporous microspheres of MoS2 synthesized by a simple one-step hydrothermal method. Direct pen writing with porous MoS2 in complex patterns enables easy, affordable, and simple fabrication of energy storage devices as and when required based on user choice toward distributed manufacturing and sustainability.

Ultrafast and Resist-Free Nanopatterning of 2D Materials by Femtosecond Laser Irradiation

The performance of two-dimensional (2D) materials is promising for electronic, photonic, and sensing devices since they possess large surface-to-volume ratios, high mechanical strength, and broadband light sensitivity. While significant advances have been made in synthesizing and transferring 2D materials onto different substrates, there is still the need for scalable patterning of 2D materials with nanoscale precision. Conventional lithography methods require protective layers such as resist or metals that can contaminate or degrade the 2D materials and deteriorate the final device performance. Current resist-free patterning methods are limited in throughput and typically require custom-made equipment. To address these limitations, we demonstrate the noncontact and resist-free patterning of platinum diselenide (PtSe₂), molybdenum disulfide (MoS₂), and graphene layers with nanoscale precision at high processing speed while preserving the integrity of the surrounding material. We use a commercial, off-the-shelf two-photon 3D printer to directly write patterns in the 2D materials with features down to 100 nm at a maximum writing speed of 50 mm/s. We successfully remove a continuous film of 2D material from a 200 μm × 200 μm substrate area in less than 3 s. Since two-photon 3D printers are becoming increasingly available in research laboratories and industrial facilities, we expect this method to enable fast prototyping of devices based on 2D materials across various research areas.

Grafting Ink for Direct Writing: Solvation Activated Covalent Functionalization of Graphene

Covalent functionalization of graphene (CFG) has shown attractive advantages in tuning the electronic, mechanical, optical, and thermal properties of graphene. However, facile, large-scale, controllable, and highly efficient CFG remains challenging and often involves highly reactive and volatile compounds, requiring complex control of the reaction conditions. Here, a diazonium-based grafting ink consisting of only two components, i.e., an aryl diazonium salt and the solvent dimethyl sulfoxide (DMSO) is presented. The efficient functionalization is attributed to the combination of the solvation of the diazonium cations by DMSO and n-doping of graphene by DMSO, thereby promoting electron transfer (ET) from graphene to the diazonium cations, resulting in the generation of aryl radicals which subsequently react with the graphene. The grafting density of CFG is controlled by the reaction time and very high levels of functionalization, up to the failing of the Tuinstra-Koenig (T-K) relation, while the functionalization layer remains at monolayer height. The grafting ink, effective for days at room temperature, can be used at ambient conditions and renders the patterning CFG by direct writing as easy as writing on paper. In combination with thermal sample treatment, reversible functionalization is possible by subsequent writing/erasing cycles.

A Direct Writing Approach for Organic Semiconductor Single-Crystal Patterns with Unique Orientation

Organic semiconductor single-crystal (OSSC) patterns with precisely controlled orientation are of great significance to the integrated fabrication of devices with high and uniform performance. However, it is still challenging to achieve purely oriented OSSC patterns due to the complex nucleation and growth process of OSSCs. Here, a general direct writing approach is presented to readily obtain high-quality OSSC patterns with unique orientation. In specific, a direct writing method is demonstrated wherein the microscale meniscus is manipulated, which makes it possible to precisely control the nucleation and growth process of the OSSC because of its comparable size to the crystal nuclei. The resulting OSSC patterns are highly crystalline and purely oriented, in which each ribbon crystal shows a deviation angle of 33° to the printing direction. The mechanism of orientation purification is revealed experimentally and theoretically, and the results show that the TCL deformation caused by the difference in wettability and adhesive force, as well as the asymmetry of fluid concentration distribution, are the key factors leading to the selective deposition and unique orientation. Moreover, organic field-effect transistors (OFETs) and polarization-sensitive photodetectors are prepared based on the OSSC patterns with unique orientation, which exhibit higher device performance compared to the non-purely oriented crystal-based OFETs.

3D Microvascularized Tissue Models by Laser-Based Cavitation Molding of Collagen

3D tissue models recapitulating human physiology are important for fundamental biomedical research, and they hold promise to become a new tool in drug development. An integrated and defined microvasculature in 3D tissue models is necessary for optimal cell functions. However, conventional bioprinting only allows the fabrication of hydrogel scaffolds containing vessel-like structures with large diameters (>100 µm) and simple geometries. Recent developments in laser photoablation enable the generation of this type of structure with higher resolution and complexity, but the photo-thermal process can compromise cell viability and hydrogel integrity. To address these limitations, the present work reports in situ 3D patterning of collagen hydrogels by femtosecond laser irradiation to create channels and cavities with diameters ranging from 20 to 60 µm. In this process, laser irradiation of the hydrogel generates cavitation gas bubbles that rearrange the collagen fibers, thereby creating stable microchannels. Such 3D channels can be formed in cell- and organoid-laden hydrogel without affecting the viability outside the lumen and can enable the formation of artificial microvasculature by the culture of endothelial cells and cell media perfusion. Thus, this method enables organs-on-a-chip and 3D tissue models featuring complex microvasculature.

Fabrication and Characterization of Line-by-Line Inscribed Tilted Fiber Bragg Gratings Using Femtosecond Laser

In this paper, we studied the basic characteristics of tilted fiber Bragg gratings (TFBGs), inscribed line-by-line. Experimental results showed that if the TFBGs were located within different planes parallel to the fiber axis, the spectra performed differently. For 2°TFBG, if it was located near the central plane, the Bragg resonance was stronger than ghost mode resonance, and the order reversed if it was located near the boundary between core and cladding. As the tilted angle increased, the range of cladding mode resonance increased. When the tilted angle was larger than 12°, the birefringence effect was observed. Based on the birefringence phenomenon, torsion characteristics were experimentally studied; the sensitivity was about 0.025 dB/degree in the linear variation range. The harmonic order of TFBGs also affected the transmission spectrum. Leaky mode resonance was observed in the 8th order TFBG, and torsion (or polarization) influenced the spectrum of the 8th order TFBG. Our research represented the theory of line-by-line inscribed TFBGs and provided an inscription guidance for TFBGs.

Direct Writing Corrugated PVC Gel Artificial Muscle via Multi-Material Printing Processes

Electroactive PVC gel is a new artificial muscle material with good performance that can mimic the movement of biological muscle in an electric field. However, traditional manufacturing methods, such as casting, prevent the broad application of this promising material because they cannot achieve the integration of the PVC gel electrode and core layer, and at the same time, it is difficult to create complex and diverse structures. In this study, a multi-material, integrated direct writing method is proposed to fabricate corrugated PVC gel artificial muscle. Inks with suitable rheological properties were developed for printing four functional layers, including core layers, electrode layers, sacrificial layers, and insulating layers, with different characteristics. The curing conditions of the printed CNT/SMP inks under different applied conditions were also discussed. The structural parameters were optimized to improve the actuating performance of the PVC gel artificial muscle. The corrugated PVC gel with a span of 1.6 mm had the best actuating performance. Finally, we printed three layers of corrugated PVC gel artificial muscle with good actuating performance. The proposed method can help to solve the inherent shortcomings of traditional manufacturing methods of PVC gel actuators. The printed structures have potential applications in many fields, such as soft robotics and flexible electronic devices.

Novel Thermally Reduced Graphene Oxide Microsupercapacitor Fabricated via Mask-Free AxiDraw Direct Writing

We demonstrate a simple method to fabricate all solid state, thermally reduced graphene oxide (TRGO) microsupercapacitors (µ-SCs) prepared using the atmospheric pressure chemical vapor deposition (APCVD) and a mask-free axiDraw sketching apparatus. The Fourier transform infrared spectroscopy (FTIR) shows the extermination of oxygen functional groups as the reducing temperature (RT) increases, while the Raman shows the presence of the defect and graphitic peaks. The electrochemical performance of the µ-SCs showed cyclic voltammetry (CV) potential window of 0–0.8 V at various scan rates of 5–1000 mVs⁻¹ with a rectangular shape, depicting characteristics of electric double layer capacitor (EDLC) behavior. The µ-SC with 14 cm⁻² (number of digits per unit area) showed a 46% increment in capacitance from that of 6 cm⁻², which is also higher than the µ-SCs with 22 and 26 cm⁻². The TRGO-500 exhibits volumetric energy and power density of 14.61 mW h cm⁻³ and 142.67 mW cm⁻³, respectively. The electrochemical impedance spectroscopy (EIS) showed the decrease in the equivalent series resistance (ESR) as a function of RT due to reduction of the resistive functional groups present in the sample. Bode plot showed a phase angel of −85° for the TRGO-500 µ-SC device. The electrochemical performance of the µ-SC devices can be tuned by varying the RT, number of digits per unity area, and connection configuration (parallel or series).

Carbon Fibers Enhance the Propagation of High Loading Nanothermites: In Situ Observation of Microscopic Combustion

A major challenge in formulating and manufacturing energetic materials lies in the balance between total energy density, energy release rate, and mechanical integrity. In this work, carbon fibers are embedded into ∼90 wt % loading Al/CuO nanothermite sticks through a simple extrusion direct writing technique. With only ∼2.5 wt % carbon fiber addition, the burn rate and heat flux were promoted >2×. In situ microscopic observation of combustion shows that the carbon fiber intercept ejected hot agglomerates near the burning surface and enhanced heat feedback to the unreacted material. This study outlines how these approaches may enhance the propagation and reduce the two-phase flow losses.

Organic Electronics Picks Up the Pace: Mask-Less, Solution Processed Organic Transistors Operating at 160 MHz

Organic printed electronics has proven its potential as an essential enabler for applications related to healthcare, entertainment, energy, and distributed intelligent objects. The possibility of exploiting solution-based and direct-writing production schemes further boosts the benefits offered by such technology, facilitating the implementation of cheap, conformable, bio-compatible electronic applications. The result shown in this work challenges the widespread assumption that such class of electronic devices is relegated to low-frequency operation, owing to the limited charge mobility of the materials and to the low spatial resolution achievable with conventional printing techniques. Here, it is shown that solution-processed and direct-written organic field-effect transistors can be carefully designed and fabricated so to achieve a maximum transition frequency of 160 MHz, unlocking an operational range that was not available before for organics. Such range was believed to be only accessible with more performing classes of semiconductor materials and/or more expensive fabrication schemes. The present achievement opens a route for cost- and energy-efficient manufacturability of flexible and conformable electronics with wireless-communication capabilities.

Guided Assembly and Patterning of Intrinsically Fluorescent Amyloid Fibers with Long-Range Order

Fibrillar amyloids exhibit a fascinating range of mechanical, optical, and electronic properties originating from their characteristic β-sheet-rich structure. Harnessing these functionalities in practical applications has so far been hampered by a limited ability to control the amyloid self-assembly process at the macroscopic scale. Here, we use core-shell electrospinning with microconfinement to assemble amyloid-hybrid fibers, consisting of densely aggregated fibrillar amyloids stabilized by a polymer shell. Up to centimeter-long hybrid fibers with micrometer diameter can be arranged into aligned and ordered arrays and deposited onto substrates or produced as free-standing networks. Properties that are characteristic of amyloids, including their high elastic moduli and intrinsic fluorescence signature, are retained in the hybrid fiber cores, and we show that they fully persist through the macroscopic fiber patterns. Our findings suggest that microlevel confinement is key for the guided assembly of amyloids from monomeric proteins.

Lubricant-Added Conductive Composite for Direct Writing of a Stretchable Electrode

Stretchable electrodes, which are essential components of next-generation electronic devices, should be highly conductive under multiaxial tensile strain, durable under repetitive stretching, and patternable for integrating stretchable devices. Herein, a lubricant-added stretchable conductive composite of a polydimethylsiloxane-based elastomer containing silver flakes is reported. The added lubricant minimizes changes in conductivity during stretching and maximizes elastic durability by reducing friction. The conductivity varies from 1933.3 S·cm^-1 at 0% strain to 307.5 S·cm^-1 at 300% uniaxial stretching and 1264.1 S·cm^-1 at 50% biaxial stretching. Furthermore, the composite exhibits high durability, even after 1000 cycles of stretching at 200%, and the conductive composite paste can be applied to fine-linewidth direct writing.

Direct Electrohydrodynamic Patterning of High-Performance All Metal Oxide Thin-Film Electronics

In this paper, we propose a scalable approach toward all-printed high-performance metal oxide thin-film transistors (TFTs), using a high-resolution electrohydrodynamic (EHD) printing process. Direct EHD micropatterning of metal oxide TFTs is based on diverse precursor solutions to form semiconducting materials (In₂O₃, In-Ga-ZnO (IGZO)), conductive metal oxide (Sn-doped In₂O₃ (ITO)), as well as aluminum oxide (Al₂O₃) gate dielectric at low temperatures. The fully printed TFT devices exhibit excellent electron transport characteristics (average electron mobilities of up to 117 cm² V^-1 s^-1), negligible hysteresis, excellent uniformity, and stable operation at low-operating voltage. Furthermore, integrated logic gates such as NOT and NAND have been printed and demonstrated. All-printed logic with individual gating and symmetric input/output behavior, which is crucial for large-scale integration, is also demonstrated. The devices and fabrication process described in this paper enable high-performance and high-reliability transparent electronics.

Direct Writing of Microfluidic Three-Dimensional Photonic Crystal Structures for Terahertz Technology Applications

The direct writing technology was used to create microfluidic three-dimensional terahertz photonic crystal structures (3D-TPCSs) with a glass cement ink, which demonstrated potentials for various terahertz technology applications. By a simple injection of liquid alloy into them, metallic 3D-TPCSs could be created easily at a low cost to solve the challenges of their creation by current approaches. These microfluidic 3D-TPCSs also possessed a specific capability of changing their terahertz properties in real time without structural changes by injecting fluidic media with different dielectric properties into their microfluidic channels, which endowed them the easy integration into various terahertz devices that require terahertz modulation for a wide range of applications. Due to their microsized channel structure and subsequent reduction of terahertz irradiation absorption by water in them, they demonstrated the potential as real time, nondestructive biological and chemical sensors to detect changes occurring in them in the fluidic media with the terahertz time-domain spectroscopy (THz-TDS).

Crystalline Niobium Carbide Superconducting Nanowires Prepared by Focused Ion Beam Direct Writing

Superconducting planar nanostructures are widely used in applications, e.g., for highly sensitive magnetometers and in basic research, e.g., to study finite size effects or vortex dynamics. In contrast, 3D superconducting nanostructures, despite their potential in quantum information processing and nanoelectronics, have been addressed only in a few pioneering experiments. This is due to the complexity of fabricating 3D nanostructures by conventional techniques such as electron-beam lithography and to the scarce number of superconducting materials available for direct-writing techniques, which enable the growth of 3D free-standing nanostructures. Here, we present a comparative study of planar nanowires and free-standing 3D nanowires fabricated by focused electron- and ion (Ga+)-beam induced deposition (FEBID and FIBID) using the precursor Nb(NMe₂)₃(N- t-Bu). FEBID nanowires contain about 67 atomic percent C, 22 atomic percent N, and 11 atomic percent Nb, while FIBID samples are composed of 43 atomic percent C, 13 atomic percent N, 15.5 atomic percent Ga, and 28.5 atomic percent Nb. Transmission electron microscopy shows that FEBID samples are amorphous, while FIBID samples exhibit a fcc NbC polycrystalline structure, with grains about 15-20 nm in diameter. Electrical transport measurements show that FEBID nanowires are highly resistive following a variable-range-hopping behavior. In contradistinction, FIBID planar nanowires become superconducting at T_c ≈ 5 K. In addition, the critical temperature of free-standing 3D nanowires is as high as T_c ≈ 11 K, which is close to the value of bulk NbC. In conclusion, FIBID-NbC is a promising material for the fabrication of superconducting nanowire single-photon detectors (SNSPD) and for the development of 3D superconductivity with applications in quantum information processing and nanoelectronics.

Direct Writing of a 90 wt% Particle Loading Nanothermite

The additive manufacturing of energetic materials has received worldwide attention. Here, an ink formulation is developed with only 10 wt% of polymers, which can bind a 90 wt% nanothermite using a simple direct-writing approach. The key additive in the ink is a hybrid polymer of poly(vinylidene fluoride) (PVDF) and hydroxy propyl methyl cellulose (HPMC) in which the former serves as an energetic initiator and a binder, and the latter is a thickening agent and the other binder, which can form a gel. The rheological shear-thinning properties of the ink are critical to making the formulation at such high loadings printable. The Young's modulus of the printed stick is found to compare favorably with that of poly(tetrafluoroethylene) (PTFE), with a particle packing density at the theoretical maximum. The linear burn rate, mass burn rate, flame temperature, and heat flux are found to be easily adjusted by varying the fuel/oxidizer ratio. The average flame temperatures are as high as ≈2800 K with near-complete combustion being evident upon examination of the postcombustion products.

Hybrid Machine Learning Method to Determine the Optimal Operating Process Window in Aerosol Jet 3D Printing

Aerosol jet printing (AJP) is a three-dimensional (3D) noncontact and direct printing technology for fabricating customized microelectronic devices on flexible substrates. Despite the capability of fine feature deposition, the complicated relationship between the main process parameters will affect the printing quality significantly in a design space. In this paper, a novel hybrid machine learning method is proposed to determine the optimal operating process window for the AJP process in various design spaces. The proposed method consists of classic machine learning methods, including experimental sampling, data clustering, classification, and knowledge transfer. In the proposed method, a two-dimensional design space is fully explored by a Latin hypercube sampling experimental design at a certain print speed. Then, the influence of the sheath gas flow rate (SHGFR) and the carrier gas flow rate (CGFR) on the printed line quality is analyzed by a K-means clustering approach, and an optimal operating process window is determined by a support vector machine. To efficiently identify more operating process windows at different print speeds, a transfer learning approach is applied to exploit relatedness between different operating process windows. Hence, at a new print speed, the number of line samples for identifying a new operating process window is greatly reduced. Finally, to balance the complex relationship among SHGFR, CGFR, and print speed, a 3D operating process window is determined by an incremental classification approach. Different from experiment-based approaches adopted in 3D printing technologies for quality optimization, the proposed method is developed based on the theory of knowledge discovery and data mining. Therefore, the knowledge in different design spaces can be fully explored and transferred for printed line quality optimization. Moreover, the data-driven-based characteristics can help the proposed method develop a guideline for quality optimization in other 3D printing technologies.

Spinning and Applications of Bioinspired Fiber Systems

Natural fiber systems provide inspirations for artificial fiber spinning and applications. Through a long process of trial and error, great progress has been made in recent years. The natural fiber itself, especially silks, and the formation mechanism are better understood, and some of the essential factors are implemented in artificial spinning methods, benefiting from advanced manufacturing technologies. In addition, fiber-based materials produced via bioinspired spinning methods find an increasingly wide range of biomedical, optoelectronic, and environmental engineering applications. This paper reviews recent developments in the spinning and application of bioinspired fiber systems, introduces natural fiber and spinning processes and artificial spinning methods, and discusses applications of artificial fiber materials. Views on remaining challenges and the perspective on future trends are also proposed.

Printing Carbon Nanotube-Embedded Silicone Elastomers via Direct Writing

Direct writing techniques for the printing of colloidal multiwalled carbon nanotubes (CNTs) embedded in polydimethylsiloxane (PDMS) were developed herein to fabricate complex structures including woodpiles, tetragonal scaffolds, and gradient mesh structures. The multiwalled CNTs served as a conductive filler and thickening agent for the printing ink. A suitable rheological behavior was obtained by mixing the CNTs with PDMS dissolved in an isopropyl alcohol solvent. A 7 wt % CNT loading in the PDMS was optimum for printing gap-spanning features at a nozzle moving speed of 20 mm/s. The printed structures, including a woodpile and gradient mesh structure, were capable of detecting changes in external mechanical pressure. Printed CNT/PDMS strips exhibit electrical actuation with good mechanical performance (strain of 8.9%) at a low actuation voltage (60 V). The performance characterization and application display demonstrated the possibility of developing custom complex CNT/PDMS structures for a broad range of applications, including soft robots and flexible electronic devices.

Healable and Foldable Carbon Nanotube/Wax Conductive Composite

In this study, a composite material with healable and foldable features is formulated to print conductive patterns on rough surfaces, such as paper, cloth, and three-dimensional (3D) printed objects. Carbon nanotubes (CNTs) are mixed with wax to formulate a solid composite for pen writing. The composite has a low percolation threshold of 2.5 wt % CNTs and can be written on various rough substrates, such as paper and cloth, to create conductive patterns for electronic conductors. Because of the strong infrared (IR) absorption of CNTs, the printed patterns can be selectively sintered by noncontact IR radiation efficiently to show great electrical conductivity. The electrical resistance of the written patterns on paper also show an insignificant increase after bending, folding, and crumpling. Furthermore, the conductive composite exhibits great healability after destructive damages. The conductivity of the damaged patterns after severe folding or knife cutting recovers to its original value with thermal or IR heating. Several examples, such as conductive tracks on paper, cloth, or 3D printed objects, are also demonstrated to show the potential of this healable conductive composite for electronic applications.

Printable Skin-Driven Mechanoluminescence Devices via Nanodoped Matrix Modification

Mechanically driven light generation is an exciting and under-exploited phenomenon with a variety of possible practical applications. However, the current driving mode of mechanoluminescence (ML) devices needs strong stimuli. Here, a flexible sensitive ML device via nanodopant elasticity modulus modification is introduced. Rigid ZnS:M²⁺ (Mn/Cu)@Al₂ O₃ microparticles are dispersed into soft poly(dimethylsiloxane) (PDMS) film and printed out to form flexible devices. For various flexible and sensitive scenes, SiO₂ nanoparticles are adopted to adjust the elasticity modulus of the PDMS matrix. The doped nanoparticles can concentrate stress to ZnS:M²⁺ (Mn/Cu)@Al₂ O₃ microparticles and achieve intense ML under weak stimuli of the moving skin. The printed nano-/microparticle-doped matrix film can achieve skin-driven ML, which can be adopted to present fetching augmented animations expressions. The printable ML film, amenable to large areas, low-cost manufacturing, and mechanical softness will be versatile on stress visualization, luminescent sensors, and open definitely new functional skin with novel augmented animations expressions, the photonic skin.

Effect of Heat Accumulation on Femtosecond Laser Reductive Sintering of Mixed CuO/NiO Nanoparticles

Direct laser-writing techniques have attracted attention for their use in two- and three-dimensional printing technologies. In this article, we report on a micropatterning process that uses femtosecond laser reductive sintering of mixed CuO/NiO nanoparticles. The writing speed, laser fluence, and incident total energy were varied to investigate the influence of heat accumulation on the micropatterns formed by these materials. Heat accumulation and the thermal history of the laser irradiation process significantly affected the material composition and the thermoelectric properties of the fabricated micropatterns. Short laser irradiation durations and high laser fluences decrease the amount of metal oxide in the micropatterns. Selective fabrication of p-type and n-type thermoelectric micropatterns was demonstrated to be possible with control of the reduction and reoxidization reactions through the control of writing speed and total irradiation energy.

Direct Writing and Characterization of Three-Dimensional Conducting Polymer PEDOT Arrays

Direct writing is an effective and versatile technique for three-dimensional (3D) fabrication of conducting polymer (CP) structures. It is precisely localized and highly controllable, thus providing great opportunities for incorporating CPs into microelectronic array devices. Herein we demonstrate 3D writing and characterization of poly(3,4-ethylenedioxythiophene)-polystyrenesulfonate (PEDOT:PSS) pillars in an array format, by using an in-house-constructed variant of scanning ion conductance microscopy (SICM). CP pillars with different aspect ratios were successfully fabricated by optimizing the writing parameters: pulling speed, pulling time, concentration of the polymer solution, and the micropipette tip diameter. Especially, super high aspect ratio pillars of around 7 μm in diameter and 5000 μm in height were fabricated, indicating a good capability of this direct writing technique. Additions of an organic solvent and a cross-linking agent contribute to a significantly enhanced water stability of the pillars, critical if the arrays were to be used in biologically relevant applications. Surface morphologies and structural analysis of CP pillars were characterized by scanning electron microscopy and Raman spectroscopy, respectively. Electrochemical properties of the individual pillars of different heights were examined by cyclic voltammetry using a double-barrel micropipette as an electrochemical cell. Exceptional mechanical properties of the pillars, such as high flexibility and robustness, were observed when bent by applying a force. The 3D pillar arrays are expected to provide versatile substrates for functionalized and integrated biological sensing and electrically addressable array devices.

Ultrafast Laser-Shock-Induced Confined Metaphase Transformation for Direct Writing of Black Phosphorus Thin Films

Few-layer black phosphorus (BP) has emerged as one of the most promising candidates for post-silicon electronic materials due to its outstanding electrical and optical properties. However, lack of large-scale BP thin films is still a major roadblock to further applications. The most widely used methods for obtaining BP thin films are mechanical exfoliation and liquid exfoliation. Herein, a method of directly synthesizing continuous BP thin films with the capability of patterning arbitrary shapes by employing ultrafast laser writing with confinement is reported. The physical mechanism of confined laser metaphase transformation is understood by molecular dynamics simulation. Ultrafast laser ablation of BP layer under confinement can induce transient nonequilibrium high-temperature and high-pressure conditions for a few picoseconds. Under optimized laser intensity, this process induces a metaphase transformation to form a crystalline BP thin film on the substrate. Raman spectroscopy, atomic force microscopy, and transmission electron microscopy techniques are utilized to characterize the morphology of the resulting BP thin films. Field-effect transistors are fabricated on the BP films to study their electrical properties. This unique approach offers a general methodology to mass produce large-scale patterned BP films with a one-step manufacturing process that has the potential to be applied to other 2D materials.

Direct Writing Electrospinning of Scaffolds with Multidimensional Fiber Architecture for Hierarchical Tissue Engineering

Nanofibrous structures have long been used as scaffolds for tissue engineering (TE) applications, due to their favorable characteristics, such as high porosity, flexibility, high cell attachment and enhanced proliferation, and overall resemblance to native extracellular matrix (ECM). Such scaffolds can be easily produced at a low cost via electrospinning (ESP), but generally cannot be fabricated with a regular and/or complex geometry, characterized by macropores and uniform thickness. We present here a novel technique for direct writing (DW) with solution ESP to produce complex three-dimensional (3D) multiscale and ultrathin (∼1 μm) fibrous scaffolds with desirable patterns and geometries. This technique was simply achieved via manipulating technological conditions, such as spinning solution, ambient conditions, and processing parameters. Three different regimes in fiber morphologies were observed, including bundle with dispersed fibers, bundle with a core of aligned fibers, and single fibers. The transition between these regimes depended on tip to collector distance (Wd) and applied voltage (V), which could be simplified as the ratio V/Wd. Using this technique, a scaffold mimicking the zonal organization of articular cartilage was further fabricated as a proof of concept, demonstrating the ability to better mimic native tissue organization. The DW scaffolds directed tissue organization and fibril matrix orientation in a zone-dependent way. Comparative expression of chondrogenic markers revealed a substantial upregulation of Sox9 and aggrecan (ACAN) on these structures compared to conventional electrospun meshes. Our novel method provides a simple way to produce customized 3D ultrathin fibrous scaffolds, with great potential for TE applications, in particular those for which anisotropy is of importance.

Direct Electron Beam Writing of Silver-Based Nanostructures

Direct writing utilizing a focused electron beam constitutes an interesting alternative to resist-based techniques, as it allows for precise and flexible growth onto any conductive substrate in a single-step process. One important challenge, however, is the identification of appropriate precursors which allow for deposition of the material of choice, e.g., for envisaged applications in nano-optics. In this regard the coinage metal silver is of particular interest since it shows a relatively high plasma frequency and, thus, excellent plasmonic properties in the visible range. By utilizing the precursor compound AgO₂Me₂Bu, direct writing of silver-based nanostructures via local electron beam induced deposition could be realized for the first time. Interestingly, the silver deposition was strongly dependent on electron dose; at low doses of 30 nC/μm² a dominant formation of pure silver crystals was observed, while at higher electron doses around 10⁴ nC/μm² large carbon contents were measured. A scheme for the enhanced silver deposition under low electron fluxes by an electronic activation of precursor dissociation below thermal CVD temperature is proposed and validated using material characterization techniques. Finally, the knowledge gained was employed to fabricate well-defined two-dimensional deposits with maximized silver content approaching 75 at. %, which was achieved by proper adjustment of the deposition parameters. The corresponding deposits consist of plasmonically active silver crystallites and demonstrate a pronounced Raman signal enhancement of the carbonaceous matrix.

Direct Writing of Microfluidic Footpaths by Pyro-EHD Printing

In this study, we report a direct writing method for the fabrication of microfluidic footpaths by pyro-electrohydrodynamic (EHD) jet printing. Here, we propose the use of a nozzle-free three-dimensional printing technique for the fabrication of printed structures that can be embedded in a variety of soft, transparent, flexible, and biocompatible polymers and thus easily integrated into lab-on-chip devices. We prove the advantage of the high resolution and flexibility of pyro-EHD printing for the realization of microfluidic channels well below the standard limit in dimension of conventional ink-jet printing technique and simply adaptable to the end-user desires in terms of geometry and materials. Starting from the description of the innovative approach proposed for the channel fabrication, we demonstrate the design, fabrication, and proof of a microfluidic matrix of interconnected channels. The method described here could be a breakthrough technology for the fabrication of in situ implantable, stretchable, and biocompatible devices, opening new routes in the field of biomedical engineering and wearable electronics.

Low-Cost Inkjet Printing Technology for the Rapid Prototyping of Transducers

Recently, there has been an upsurge in efforts dedicated to developing low-cost flexible electronics by exploiting innovative materials and direct printing technologies. This interest is motivated by the need for low-cost mass-production, shapeable, and disposable devices, and the rapid prototyping of electronics and sensors. This review, following a short overview of main printing processes, reports examples of the development of flexible transducers through low-cost inkjet printing technology.

Low-Voltage Continuous Electrospinning Patterning

Electrospinning is a versatile technique for the construction of microfibrous and nanofibrous structures with considerable potential in applications ranging from textile manufacturing to tissue engineering scaffolds. In the simplest form, electrospinning uses a high voltage of tens of thousands volts to draw out ultrafine polymer fibers over a large distance. However, the high voltage limits the flexible combination of material selection, deposition substrate, and control of patterns. Prior studies show that by performing electrospinning with a well-defined "near-field" condition, the operation voltage can be decreased to the kilovolt range, and further enable more precise patterning of fibril structures on a planar surface. In this work, by using solution dependent "initiators", we demonstrate a further lowering of voltage with an ultralow voltage continuous electrospinning patterning (LEP) technique, which reduces the applied voltage threshold to as low as 50 V, simultaneously permitting direct fiber patterning. The versatility of LEP is shown using a wide range of combination of polymer and solvent systems for thermoplastics and biopolymers. Novel functionalities are also incorporated when a low voltage mode is used in place of a high voltage mode, such as direct printing of living bacteria; the construction of suspended single fibers and membrane networks. The LEP technique reported here should open up new avenues in the patterning of bioelements and free-form nano- to microscale fibrous structures.

Robotic Deposition of TiO2 Films on Flexible Substrates from Hybrid Inks: Investigation of Synthesis-Processing-Microstructure-Photocatalytic Relationships

TiO2 is an important material widely used in optoelectronic devices due to its semiconducting and photocatalytic properties, nontoxicity, and chemically inert nature. Some indicative applications include water purification systems and energy harvesting. The use of solution, water-based inks for the direct writing of TiO2 on flexible substrates is of paramount importance since it enables low-cost and low-energy intensive large-area manufacturing, compatible with roll-to-roll processing. In this work we study the effect of crystalline TiO2 and polymer addition on the rheological and direct writing properties of Ti-organic/TiO2 inks. We also report on the bridging crystallite formation from the Ti-organic precursor into the TiO2 crystalline phase, under ultraviolet (UV) exposure or mild heat treatments up to 150 °C. Such crystallite formation is found to be enhanced by polymers with strong polarity and pKα such as polyacrylic acid (PAA). X-ray diffraction (XRD) coupled with Raman and X-ray photoelectron (XPS) spectroscopy are used to investigate the crystalline-phase transformation dependence based on the initial TiO2 crystalline-phase concentration and polymer addition. Transmission electron microscopy imaging and selected area electron diffraction patterns confirm the crystalline nature of such bridging printed structures. The obtained inks are patterned on flexible substrates using nozzle-based robotic deposition, a lithography-free, additive manufacturing technique that allows the direct writing of material in specific, digitally predefined, substrate locations. Photocatalytic degradation of methylene blue solutions highlights the potential of the studied films for chemical degradation applications, from low-cost environmentally friendly materials systems.

Direct Writing of Patterned, Lead-Free Nanowire Aligned Flexible Piezoelectric Device

A high-performance flexible piezoelectric nanogenerator (PNG) is fabricated by a direct writing method, which acquires both patterned piezoelectric structure and aligned piezoelectric nanowires simultaneously. The voltage output of the as-prepared PNG is nearly 400% compared with that of the traditional spin-coated device due to the effective utilization of stress. This facile printing approach provides an efficient strategy for significant improvement of the piezoresponse.

Vertical, capacitive microelectromechanical switches produced via direct writing of copper wires

Three-dimensional (3D) direct writing based on the meniscus-confined electrodeposition of copper metal wires was used in this study to develop vertical capacitive microelectromechanical switches. Vertical microelectromechanical switches reduce the form factor and increase the area density of such devices in integrated circuits. We studied the electromechanical characteristics of such vertical switches by exploring the dependence of switching voltage on various device structures, particularly with regard to the length, wire diameter, and the distance between the two wires. A simple model was found to match the experimental measurements made in this study. We found that the electrodeposited copper microwires exhibit a good elastic modulus close to that of bulk copper. By optimizing the 3D structure of the electrodes, a volatile electromechanical switch with a sub-5 V switching voltage was demonstrated in a vertical microscale switch with a gap distance as small as 100 nm created with a pair of copper wires with diameters of ~1 μm and heights of 25 μm. This study establishes an innovative approach to construct microelectromechanical systems with arbitrary 3D microwire structures for various applications, including the demonstrated volatile and nonvolatile microswitches.

Direct-Writing of Cu Nano-Patterns with an Electron Beam

We demonstrate direct electron beam writing of a nano-scale Cu pattern on a surface with a thin aqueous layer of CuSO4 solution. Electron beams are highly maneuverable down to nano-scales. Aqueous solutions facilitate a plentiful metal ion supply for practical industrial applications, which may require continued reliable writing of sophisticated patterns. A thin aqueous layer on a surface helps to confine the writing on the surface. For this demonstration, liquid sample holder (K-kit) for transmission electron microscope (TEM) was employed to form a sealed space in a TEM. The aqueous CuSO4 solution inside the sample holder was allowed to partially dry until a uniform thin layer was left on the surface. The electron beam thus reduced Cu ions in the solution to form the desired patterns. Furthermore, the influence of e-beam exposure time and CuSO4(aq) concentration on the Cu reduction was studied in this work. Two growth stages of Cu were shown in the plot of Cu thickness versus e-beam exposure time. The measured Cu reduction rate was found to be proportional to the CuSO4(aq) concentration.

Direct Writing of Three-Dimensional Macroporous Photonic Crystals on Pressure-Responsive Shape Memory Polymers

Here we report a single-step direct writing technology for making three-dimensional (3D) macroporous photonic crystal patterns on a new type of pressure-responsive shape memory polymer (SMP). This approach integrates two disparate fields that do not typically intersect: the well-established templating nanofabrication and shape memory materials. Periodic arrays of polymer macropores templated from self-assembled colloidal crystals are squeezed into disordered arrays in an unusual shape memory "cold" programming process. The recovery of the original macroporous photonic crystal lattices can be triggered by direct writing at ambient conditions using both macroscopic and nanoscopic tools, like a pencil or a nanoindenter. Interestingly, this shape memory disorder-order transition is reversible and the photonic crystal patterns can be erased and regenerated hundreds of times, promising the making of reconfigurable/rewritable nanooptical devices. Quantitative insights into the shape memory recovery of collapsed macropores induced by the lateral shear stresses in direct writing are gained through fundamental investigations on important process parameters, including the tip material, the critical pressure and writing speed for triggering the recovery of the deformed macropores, and the minimal feature size that can be directly written on the SMP membranes. Besides straightforward applications in photonic crystal devices, these smart mechanochromic SMPs that are sensitive to various mechanical stresses could render important technological applications ranging from chromogenic stress and impact sensors to rewritable high-density optical data storage media.

Biocompatible enzymatic roller pens for direct writing of biocatalytic materials: "do-it-yourself" electrochemical biosensors

The development of enzymatic-ink-based roller pens for direct drawing of biocatalytic sensors, in general, and for realizing renewable glucose sensor strips, in particular, is described. The resulting enzymatic-ink pen allows facile fabrication of high-quality inexpensive electrochemical biosensors of any design by the user on a wide variety of surfaces having complex textures with minimal user training. Unlike prefabricated sensors, this approach empowers the end user with the ability of "on-demand" and "on-site" designing and fabricating of biocatalytic sensors to suit their specific requirement. The resulting devices are thus referred to as "do-it-yourself" sensors. The bio-active pens produce highly reproducible biocatalytic traces with minimal edge roughness. The composition of the new enzymatic inks has been optimized for ensuring good biocatalytic activity, electrical conductivity, biocompati-bility, reproducible writing, and surface adherence. The resulting inks are characterized using spectroscopic, viscometric, electrochemical, thermal and microscopic techniques. Applicability to renewable blood glucose testing, epidermal glucose monitoring, and on-leaf phenol detection are demonstrated in connection to glucose oxidase and tyrosinase-based carbon inks. The "do-it-yourself" renewable glucose sensor strips offer a "fresh," reproducible, low-cost biocatalytic sensor surface for each blood test. The ability to directly draw biocatalytic conducting traces even on unconventional surfaces opens up new avenues in various sensing applications in low-resource settings and holds great promise for diverse healthcare, environmental, and defense domains.

Bio-inspired direct patterning functional nanothin microlines: controllable liquid transfer

Developing a general and low-cost strategy that enables direct patterning of microlines with nanometer thickness from versatile liquid-phase functional materials and precise positioning of them on various substrates remains a challenge. Herein, with inspiration from the oriental wisdom to control ink transfer by Chinese brushes, we developed a facile and general writing strategy to directly pattern various functional microlines with homogeneous distribution and nanometer-scale thickness. It is demonstrated that the width and thickness of the microlines could be well-controlled by tuning the writing method, providing guidance for the adaptation of this technique to various systems. It is also shown that various functional liquid-phase materials, such as quantum dots, small molecules, polymers, and suspensions of nanoparticles, could directly write on the substrates with intrinsic physicochemical properties well-preserved. Moreover, this technique enabled direct patterning of liquid-phase materials on certain microdomains, even in multiple layered style, thus a microdomain localized chemical reaction and the patterned surface chemical modification were enabled. This bio-inspired direct writing device will shed light on the template-free printing of various functional micropatterns, as well as the integrated functional microdevices.

Direct writing on paper of foldable capacitive touch pads with silver nanowire inks

Paper-based capacitive touch pads can be fabricated utilizing high-concentration silver nanowire inks needle-printed directly onto paper substrates through a 2D programmable platform. Post deposition, silver nanowire tracks can be photonically sintered using a camera flash to reduce sheet resistance similar to thermal sintering approaches. Touch pad sensors on a variety of paper substrates can be achieved with optimized silver nanowire tracks. Rolling and folding trials, which yielded only modest changes in capacitance and no loss of function, coupled with touch pad functionality on curved surfaces, suggest sufficient flexibility and durability for paper substrate touch pads to be used in diverse applications. A simplified model to predict touch pad capacitance variation ranges with differing touch conditions was developed, with good agreement against experimental results. Such paper-based touch pads have the advantage of simple structure, easy fabrication, and fast sintering, which holds promise for numerous commercial applications including low-cost portable devices where ultrathin and lightweight features, coupled with reliable bending stability are desirable.

Printing low-melting-point alloy ink to directly make a solidified circuit or functional device with a heating pen

A new method to directly print out a solidified electronic circuit through low-melting-point metal ink is proposed. A functional pen with heating capability was fabricated. Several typical thermal properties of the alloy ink Bi₃₅In_48.6Sn₁₆Zn_0.4 were measured and evaluated. Owing to the specifically selected melting point of the ink, which is slightly higher than room temperature, various electronic devices, graphics or circuits can be manufactured in a short period of time and then rapidly solidified by cooling in the surrounding air. The liquid-solid phase change mechanism of the written lines was experimentally characterized using a scanning electron microscope. In order to determine the matching substrate, wettability between the metal ink Bi₃₅In_48.6Sn₁₆Zn_0.4 and several materials, including mica plate and silicone rubber, was investigated. The resistance-temperature curve of a printed resistor indicated its potential as a temperature control switch. Furthermore, the measured reflection coefficient of a printed double-diamond antenna accords well with the simulated result. With unique merits such as no pollution, no requirement for encapsulation and easy recycling, the present printing approach is an important supplement to current printed electronics and has enormous practical value in the future.