3D Printed Functional and Biological Materials on Moving Freeform Surfaces

Conventional 3D printing technologies typically rely on open‐loop, calibrate‐then‐print operation procedures. An alternative approach is adaptive 3D printing, which is a closed‐loop method that combines real‐time feedback control and direct ink writing of functional materials in order to fabricate devices on moving freeform surfaces. Here, it is demonstrated that the changes of states in the 3D printing workspace in terms of the geometries and motions of target surfaces can be perceived by an integrated robotic system aided by computer vision. A hybrid fabrication procedure combining 3D printing of electrical connects with automatic pick‐and‐placing of surface‐mounted electronic components yields functional electronic devices on a free‐moving human hand. Using this same approach, cell‐laden hydrogels are also printed on live mice, creating a model for future studies of wound‐healing diseases. This adaptive 3D printing method may lead to new forms of smart manufacturing technologies for directly printed wearable devices on the body and for advanced medical treatments.     

Elevated‐Temperature 3D Printing of Hybrid Solid‐State Electrolyte for Li‐Ion Batteries

While 3D printing of rechargeable batteries has received immense interest in advancing the next generation of 3D energy storage devices, challenges with the 3D printing of electrolytes still remain. Additional processing steps such as solvent evaporation were required for earlier studies of electrolyte fabrication, which hindered the simultaneous production of electrode and electrolyte in an all‐3D‐printed battery. Here, a novel method is demonstrated to fabricate hybrid solid‐state electrolytes using an elevated‐temperature direct ink writing technique without any additional processing steps. The hybrid solid‐state electrolyte consists of solid poly(vinylidene fluoride‐hexafluoropropylene) matrices and a Li⁺‐conducting ionic‐liquid electrolyte. The ink is modified by adding nanosized ceramic fillers to achieve the desired rheological properties. The ionic conductivity of the inks is 0.78 × 10 ^?3 S cm^?1. Interestingly, a continuous, thin, and dense layer is discovered to form between the porous electrolyte layer and the electrode, which effectively reduces the interfacial resistance of the solid‐state battery. Compared to the traditional methods of solid‐state battery assembly, the directly printed electrolyte helps to achieve higher capacities and a better rate performance. The direct fabrication of electrolyte from printable inks at an elevated temperature will shed new light on the design of all‐3D‐printed batteries for next‐generation electronic devices.     

Printing Polymer Nanocomposites and Composites in Three Dimensions

Recent advances in materials science and three‐dimensional (3D) printing hold great promises to conceive new classes of multifunctional materials and components for functional devices and products. Various functionalities (e.g., mechanical, electrical, and thermal properties, magnetism) can be offered by the nano‐ and micro‐reinforcements to the non‐functional pure printing materials for the realization of advanced materials and innovative systems. In addition, the ability to print 3D structures in a layer‐by‐layer manner enables manufacturing of highly‐customized complex features and allows an efficient control over the properties of fabricated structures. Here, the authors present a brief overview mainly over the latest progresses in 3D printing of multifunctional polymer nanocomposites and microfiber‐reinforced composites including the benefits, limitations, and potential applications. Only those 3D printing techniques that are compatible with polymer nanocomposites and composites, that is, materials that have already been used as printing materials, are introduced. The very hot topic of 3D printing of thermoplastic composites featuring continuous microfibers is also briefly introduced.     

3D Printed Photoresponsive Devices Based on Shape Memory Composites

Compared with traditional stimuli‐responsive devices with simple planar or tubular geometries, 3D printed stimuli‐responsive devices not only intimately meet the requirement of complicated shapes at macrolevel but also satisfy various conformation changes triggered by external stimuli at the microscopic scale. However, their development is limited by the lack of 3D printing functional materials. This paper demonstrates the 3D printing of photoresponsive shape memory devices through combining fused deposition modeling printing technology and photoresponsive shape memory composites based on shape memory polymers and carbon black with high photothermal conversion efficiency. External illumination triggers the shape recovery of 3D printed devices from the temporary shape to the original shape. The effect of materials thickness and light density on the shape memory behavior of 3D printed devices is quantified and calculated. Remarkably, sunlight also triggers the shape memory behavior of these 3D printed devices. This facile printing strategy would provide tremendous opportunities for the design and fabrication of biomimetic smart devices and soft robotics.     

3D Printing of Liquid Crystal Elastomeric Actuators with Spatially Programed Nematic Order

Liquid crystal elastomers (LCEs) are soft materials capable of large, reversible shape changes, which may find potential application as artificial muscles, soft robots, and dynamic functional architectures. Here, the design and additive manufacturing of LCE actuators (LCEAs) with spatially programed nematic order that exhibit large, reversible, and repeatable contraction with high specific work capacity are reported. First, a photopolymerizable, solvent‐free, main‐chain LCE ink is created via aza‐Michael addition with the appropriate viscoelastic properties for 3D printing. Next, high operating temperature direct ink writing of LCE inks is used to align their mesogen domains along the direction of the print path. To demonstrate the power of this additive manufacturing approach, shape‐morphing LCEA architectures are fabricated, which undergo reversible planar‐to‐3D and 3D‐to‐3D′ transformations on demand, that can lift significantly more weight than other LCEAs reported to date.     

3D Printed Polymer Photodetectors

Extrusion‐based 3D printing, an emerging technology, has been previously used in the comprehensive fabrication of light‐emitting diodes using various functional inks, without cleanrooms or conventional microfabrication techniques. Here, polymer‐based photodetectors exhibiting high performance are fully 3D printed and thoroughly characterized. A semiconducting polymer ink is printed and optimized for the active layer of the photodetector, achieving an external quantum efficiency of 25.3%, which is comparable to that of microfabricated counterparts and yet created solely via a one‐pot custom built 3D‐printing tool housed under ambient conditions. The devices are integrated into image sensing arrays with high sensitivity and wide field of view, by 3D printing interconnected photodetectors directly on flexible substrates and hemispherical surfaces. This approach is further extended to create integrated multifunctional devices consisting of optically coupled photodetectors and light‐emitting diodes, demonstrating for the first time the multifunctional integration of multiple semiconducting device types which are fully 3D printed on a single platform. The 3D‐printed optoelectronic devices are made without conventional microfabrication facilities, allowing for flexibility in the design and manufacturing of next‐generation wearable and 3D‐structured optoelectronics, and validating the potential of 3D printing to achieve high‐performance integrated active electronic materials and devices.     

3D Printing of Living Responsive Materials and Devices

3D printing has been intensively explored to fabricate customized structures of responsive materials including hydrogels, liquid‐crystal elastomers, shape‐memory polymers, and aqueous droplets. Herein, a new method and material system capable of 3D‐printing hydrogel inks with programed bacterial cells as responsive components into large‐scale (3 cm), high‐resolution (30 μm) living materials, where the cells can communicate and process signals in a programmable manner, are reported. The design of 3D‐printed living materials is guided by quantitative models that account for the responses of programed cells in printed microstructures of hydrogels. Novel living devices are further demonstrated, enabled by 3D printing of programed cells, including logic gates, spatiotemporally responsive patterning, and wearable devices.     

Two-Way 4D Printing: A Review on the Reversibility of 3D-Printed Shape Memory Materials

The rapid development of additive manufacturing and advances in shape memory materials have fueled the progress of four-dimensional (4D) printing. With the right external stimulus, the need for human interaction, sensors, and batteries will be eliminated, and by using additive manufacturing, more complex devices and parts can be produced. With the current understanding of shape memory mechanisms and with improved design for additive manufacturing, reversibility in 4D printing has recently been proven to be feasible. Conventional one-way 4D printing requires human interaction in the programming (or shape-setting) phase, but reversible 4D printing, or two-way 4D printing, will fully eliminate the need for human interference, as the programming stage is replaced with another stimulus. This allows reversible 4D printed parts to be fully dependent on external stimuli; parts can also be potentially reused after every recovery, or even used in continuous cycles—an aspect that carries industrial appeal. This paper presents a review on the mechanisms of shape memory materials that have led to 4D printing, current findings regarding 4D printing in alloys and polymers, and their respective limitations. The reversibility of shape memory materials and their feasibility to be fabricated using three-dimensional (3D) printing are summarized and critically analyzed. For reversible 4D printing, the methods of 3D printing, mechanisms used for actuation, and strategies to achieve reversibility are also highlighted. Finally, prospective future research directions in reversible 4D printing are suggested.     

When 2D Materials Meet Molecules: Opportunities and Challenges of Hybrid Organic/Inorganic van der Waals Heterostructures

van der Waals heterostructures, composed of vertically stacked inorganic 2D materials, represent an ideal platform to demonstrate novel device architectures and to fabricate on‐demand materials. The incorporation of organic molecules within these systems holds an immense potential, since, while nature offers a finite number of 2D materials, an almost unlimited variety of molecules can be designed and synthesized with predictable functionalities. The possibilities offered by systems in which continuous molecular layers are interfaced with inorganic 2D materials to form hybrid organic/inorganic van der Waals heterostructures are emphasized. Similar to their inorganic counterpart, the hybrid structures have been exploited to put forward novel device architectures, such as antiambipolar transistors and barristors. Moreover, specific molecular groups can be employed to modify intrinsic properties and confer new capabilities to 2D materials. In particular, it is highlighted how molecular self‐assembly at the surface of 2D materials can be mastered to achieve precise control over position and density of (molecular) functional groups, paving the way for a new class of hybrid functional materials whose final properties can be selected by careful molecular design.     

Recent Progress in Biomimetic Additive Manufacturing Technology: From Materials to Functional Structures

Nature has developed high‐performance materials and structures over millions of years of evolution and provides valuable sources of inspiration for the design of next‐generation structural materials, given the variety of excellent mechanical, hydrodynamic, optical, and electrical properties. Biomimicry, by learning from nature's concepts and design principles, is driving a paradigm shift in modern materials science and technology. However, the complicated structural architectures in nature far exceed the capability of traditional design and fabrication technologies, which hinders the progress of biomimetic study and its usage in engineering systems. Additive manufacturing (three‐dimensional (3D) printing) has created new opportunities for manipulating and mimicking the intrinsically multiscale, multimaterial, and multifunctional structures in nature. Here, an overview of recent developments in 3D printing of biomimetic reinforced mechanics, shape changing, and hydrodynamic structures, as well as optical and electrical devices is provided. The inspirations are from various creatures such as nacre, lobster claw, pine cone, flowers, octopus, butterfly wing, fly eye, etc., and various 3D‐printing technologies are discussed. Future opportunities for the development of biomimetic 3D‐printing technology to fabricate next‐generation functional materials and structures in mechanical, electrical, optical, and biomedical engineering are also outlined.     

A 3D Self‐Shaping Strategy for Nanoresolution Multicomponent Architectures

3D printing or fabrication pursues the essential surface behavior manipulation of droplets or a liquid for rapidly and precisely constructing 3D multimaterial architectures. Further development of 3D fabrication desires a self‐shaping strategy that can heterogeneously integrate functional materials with disparate electrical or optical properties. Here, a 3D liquid self‐shaping strategy is reported for rapidly patterning materials over a series of compositions and accurately achieving micro‐ and nanoscale structures. The predesigned template selectively pins the droplet, and the surface energy minimization drives the self‐shaping processing. The as‐prepared 3D circuits assembled by silver nanoparticles carry a current of 208–448 µA at 0.01 V impressed voltage, while the 3D architectures achieved by two different quantum dots show noninterfering optical properties with feature resolution below 3 µm. This strategy can facilely fabricate micro‐nanogeometric patterns without a modeling program, which will be of great significance for the development of 3D functional devices.     

Nanomaterial Patterning in 3D Printing

The synergistic integration of nanomaterials with 3D printing technologies can enable the creation of architecture and devices with an unprecedented level of functional integration. In particular, a multiscale 3D printing approach can seamlessly interweave nanomaterials with diverse classes of materials to impart, program, or modulate a wide range of functional properties in an otherwise passive 3D printed object. However, achieving such multiscale integration is challenging as it requires the ability to pattern, organize, or assemble nanomaterials in a 3D printing process. This review highlights the latest advances in the integration of nanomaterials with 3D printing, achieved by leveraging mechanical, electrical, magnetic, optical, or thermal phenomena. Ultimately, it is envisioned that such approaches can enable the creation of multifunctional constructs and devices that cannot be fabricated with conventional manufacturing approaches.     

Rapid Open‐Air Digital Light 3D Printing of Thermoplastic Polymer

3D printing has witnessed a new era in which highly complexed customized products become reality. Realizing its ultimate potential requires simultaneous attainment of both printing speed and product versatility. Among various printing techniques, digital light processing (DLP) stands out in its high speed but is limited to intractable light curable thermosets. Thermoplastic polymers, despite their reprocessibility that allows more options for further manipulation, are restricted to intrinsically slow printing methods such as fused deposition modeling. Extending DLP to thermoplastics is highly desirable, but is challenging due to the need to reach rapid liquid–solid separation during the printing process. Here, a successful attempt at DLP printing of thermoplastic polymers is reported, realized by controlling two competing kinetic processes (polymerization and polymer dissolution) simultaneously occurring during printing. With a selected monomer, 4‐acryloylmorpholine (ACMO), printing of thermoplastic 3D scaffolds is demonstrated, which can be further converted into various materials/devices utilizing its unique water‐soluble characteristic. The ultralow viscosity of ACMO, along with surface oxygen inhibition, allows rapid liquid flow toward high‐speed open‐air printing. The process simplicity, enabling mechanism, and material versatility broaden the scope of 3D printing in constructing functional 3D devices including reconfigurable antenna, shape‐shifting structures, and microfluidics.     

Hybrid Nanostructures for Energy Storage Applications

Materials engineering plays a key role in the field of energy storage. In particular, engineering materials at the nanoscale offers unique properties resulting in high performance electrodes and electrolytes in various energy storage devices. Consequently, considerable efforts have been made in recent years to fulfill the future requirements of electrochemical energy storage using these advanced materials. Various multi‐functional hybrid nanostructured materials are currently being studied to improve energy and power densities of next generation storage devices. This review describes some of the recent progress in the synthesis of different types of hybrid nanostructures using template assisted and non‐template based methods. The potential applications and recent research efforts to utilize these hybrid nanostructures to enhance the electrochemical energy storage properties of Li‐ion battery and supercapacitor are discussed. This review also briefly outlines some of the recent progress and new approaches being explored in the techniques of fabrication of 3D battery structures using hybrid nanoarchitectures.     

3D Printed Stretchable Tactile Sensors

The development of methods for the 3D printing of multifunctional devices could impact areas ranging from wearable electronics and energy harvesting devices to smart prosthetics and human–machine interfaces. Recently, the development of stretchable electronic devices has accelerated, concomitant with advances in functional materials and fabrication processes. In particular, novel strategies have been developed to enable the intimate biointegration of wearable electronic devices with human skin in ways that bypass the mechanical and thermal restrictions of traditional microfabrication technologies. Here, a multimaterial, multiscale, and multifunctional 3D printing approach is employed to fabricate 3D tactile sensors under ambient conditions conformally onto freeform surfaces. The customized sensor is demonstrated with the capabilities of detecting and differentiating human movements, including pulse monitoring and finger motions. The custom 3D printing of functional materials and devices opens new routes for the biointegration of various sensors in wearable electronics systems, and toward advanced bionic skin applications.     

A Review on the 3D Printing of Functional Structures for Medical Phantoms and Regenerated Tissue and Organ Applications

Medical models, or “phantoms,” have been widely used for medical training and for doctor-patient interactions. They are increasingly used for surgical planning, medical computational models, algorithm verification and validation, and medical devices development. Such new applications demand high-fidelity, patient-specific, tissue-mimicking medical phantoms that can not only closely emulate the geometric structures of human organs, but also possess the properties and functions of the organ structure. With the rapid advancement of three-dimensional (3D) printing and 3D bioprinting technologies, many researchers have explored the use of these additive manufacturing techniques to fabricate functional medical phantoms for various applications. This paper reviews the applications of these 3D printing and 3D bioprinting technologies for the fabrication of functional medical phantoms and bio-structures. This review specifically discusses the state of the art along with new developments and trends in 3D printed functional medical phantoms (i.e., tissue-mimicking medical phantoms, radiologically relevant medical phantoms, and physiological medical phantoms) and 3D bio-printed structures (i.e., hybrid scaffolding materials, convertible scaffolds, and integrated sensors) for regenerated tissues and organs.     

Adaptable and Reprogrammable Surfaces

Establishing control over chemical reactions on interfaces is a key challenge in contemporary surface and materials science, in particular when introducing well‐defined functionalities in a reversible fashion. Reprogrammable, adaptable and functional interfaces require sophisticated chemistries to precisely equip them with specific functionalities having tailored properties. In the last decade, reversible chemistries—both covalent and noncovalent—have paved the way to precision functionalize 2 or 3D structures that provide both spatial and temporal control. A critical literature assessment reveals that methodologies for writing and erasing substrates exist, yet are still far from reaching their full potential. It is thus critical to assess the current status and to identify avenues to overcome the existing limitations. Herein, the current state‐of‐the‐art in the field of reversible chemistry on surfaces is surveyed, while concomitantly identifying the challenges—not only synthetic but also in current surface characterization methods. The potential within reversible chemistry on surfaces to function as true writeable memories devices is identified, and the latest developments in readout technologies are discussed. Finally, we explore how spatial and temporal control over reversible, light‐induced chemistries has the potential to drive the future of functional interface design, especially when combined with powerful laser lithographic applications.     

One‐Dimensional Dielectric/Metallic Hybrid Materials for Photonic Applications

Explorations of 1D nanostructures have led to great progress in the area of nanophotonics in the past decades. Based on either dielectric or metallic materials, a variety of 1D photonic devices have been developed, such as nanolasers, waveguides, optical switches, and routers. What's interesting is that these dielectric systems enjoy low propagation losses and usually possess active optical performance, but they have a diffraction‐limited field confinement. Alternatively, metallic systems can guide light on deep subwavelength scales, but they suffer from high metallic absorption and can work as passive devices only. Thus, the idea to construct a hybrid system that combines the merits of both dielectric and metallic materials was proposed. To date, unprecedented optical properties have been achieved in various 1D hybrid systems, which manifest great potential for functional nanophotonic devices. Here, the focus is on recent advances in 1D dielectric/metallic hybrid systems, with a special emphasis on novel structure design, rational fabrication techniques, unique performance, as well as their wide application in photonic components. Gaining a better understanding of hybrid systems would benefit the design of nanophotonic components aimed at optical information processing.     

Ionic‐Liquid‐Assisted Sonochemical Synthesis of Carbon‐Nanotube‐Based Nanohybrids: Control in the Structures and Interfacial Characteristics

A versatile, facile, and rapid synthetic method of advanced carbon nanotube (CNT)‐based nanohybrid fabrication, or the so‐called ionic‐liquid‐assisted sonochemical method (ILASM), which combines the supramolecular chemistry between ionic liquids (ILs) and CNTs with sonochemistry for the control in the size and amount of uniformly decorated nanoparticles (NPs) and interfacial engineering, is reported. The excellence in electrocatalysis of hybrid materials with well‐designed nanostructures and favorable interfaces is demonstrated by applying them to electrochemical catalysis. The synthetic method discussed in this report has an important and immediate impact not only on the design and synthesis of functional hybrid nanomaterials by supramolecular chemistry and sonochemistry but also on applications of the same into electrochemical devices such as sensors, fuel cells, solar cells, actuators, batteries, and capacitors.     

A 2D Conductive Organic–Inorganic Hybrid with Extraordinary Volumetric Capacitance at Minimal Swelling

Rational design and synthesis of 2D organic–inorganic hybrid materials is important for transformative technological advances for energy storage. Here, a 2D conductive hybrid lamella and its intercalation properties for thin‐film supercapacitors are reported. The 2D organic–inorganic hybrid lamella comprises periodically stacked 2D nanosheets with 11.81 Å basal spacing, and is electronically conductive (605 S m^?1). In contrast to the pre‐existing organic‐based 2D materials, this material has extremely low gas‐permeable porosity (16.5 m² g^?1) in contrast to the high ionic accessibility. All these structural features collectively contribute to the high capacitances up to 732 F cm^?3, combined with small structural swelling at as low as 4.8% and good stability. At a discharge time of 6 s, the thin‐film intercalation electrode delivers an energy density of 24 mWh cm^?3, which universally outperforms the surface‐dominant capacitive processes in porous carbons.