Photocurable 3D Printing of High Toughness and Self-Healing Hydrogels for Customized Wearable Flexible Sensors

Currently, most customized hydrogels can only be processed via extrusion-based 3D printing techniques, which is limited by printing efficiency and resolution. Here, a simple strategy for the rapid fabrication of customized hydrogels using a photocurable 3D printing technique is presented. This technique has been rarely used because the presence of water increases the molecular distance between the polymer chains and reduces the monomer polymerization rate, resulting in the failure of rapid solid-liquid separation during printing. Although adding cross-linkers to printing inks can effectively accelerate 3D cross-linked network formation, chemical cross-linking may result in reduced toughness and self-healing ability of the hydrogel. Therefore, an interpenetrated-network hydrogel based on non-covalent interactions is designed to form physical cross-links, affording fast solid-liquid separation. Poly(acrylic acid (AA)-N-vinyl-2-pyrrolidone (NVP)) and carboxymethyl cellulose (CMC) are cross-linked via Zn²⁺-ligand coordination and hydrogen bonding; the resulting mixed AA-NVP/CMC solution is used as the printing ink. The printed poly(AA-NVP/CMC) hydrogel exhibited high tensile toughness (3.38 MJ m⁻³) and superior self-healing ability (healed stress: 81%; healed strain: 91%). Some objects like manipulator are successfully customized by photocurable 3D printing using hydrogels with high toughness and complex structures. This high-performance hydrogel has great potential for application in flexible wearable sensors.     

3D Wearable Fabric-Based Micro-Supercapacitors with Ultra-High Areal Capacitance

Miniaturized electronics require integrated unit configuration in very limited space, where energy storage per unit area is thus extremely critical. Micro-supercapacitors (MSCs), mainly established on planar substrates, are superior but still suffer from limited areal capacitance. Herein, a novel strategy is introduced to construct high cross-section MSCs using 3D fabrics as the porous skeleton. Interdigitated poly(3,4-ethylenedioxythiophene): poly(styrenesulfonate) (PEDOT:PSS) is patterned on 3D fabrics to achieve continuous conductive networks, while MnO₂ microspheres epitaxially grown on PEDOT:PSS are fully exposed to electrolyte with the support of fabric fibers. The unique architecture can utilize more active sites of thick electrodes and the high conductivity of interpenetrating fiber networks. The resulting fabric-based MSCs demonstrate ultra-high areal capacitance of 135.4 mF cm⁻², which is 3.5 times that of devices on polyethylene terephthalate substrates and is among the highest values for planar-based MSCs using the same interdigital geometry. Moreover, the flexible fabrics endow MSCs with extremely high bending stability with 94% capacitance retention even after 3000 cycles. These figures-of-merit enable fabric-based MSCs promising to be used in the next-generation of wearable electronics.     

3D‐Printed All‐Fiber Li‐Ion Battery toward Wearable Energy Storage

Conventional bulky and rigid power systems are incapable of meeting flexibility and breathability requirements for wearable applications. Despite the tremendous efforts dedicated to developing various 1D energy storage devices with sufficient flexibility, challenges remain pertaining to fabrication scalability, cost, and efficiency. Here, a scalable, low‐cost, and high‐efficiency 3D printing technology is applied to fabricate a flexible all‐fiber lithium‐ion battery (LIB). Highly viscous polymer inks containing carbon nanotubes and either lithium iron phosphate (LFP) or lithium titanium oxide (LTO) are used to print LFP fiber cathodes and LTO fiber anodes, respectively. Both fiber electrodes demonstrate good flexibility and high electrochemical performance in half‐cell configurations. All‐fiber LIB can be successfully assembled by twisting the as‐printed LFP and LTO fibers together with gel polymer as the quasi‐solid electrolyte. The all‐fiber device exhibits a high specific capacity of ≈110 mAh g^?1 at a current density of 50 mA g^?1 and maintains a good flexibility of the fiber electrodes, which can be potentially integrated into textile fabrics for future wearable electronic applications.     

3D Printed Actuators: Reversibility,Relaxation, and Ratcheting

Additive manufacturing strives to combine any combination of materials into 3D functional structures and devices, ultimately opening up the possibility of 3D printed machines. It remains difficult to actuate such devices, thus limiting the scope of 3D printed machines to passive devices or necessitating the incorporation of external actuators that are manufactured differently. Here, 3D printed hybrid thermoplast/conducter bilayers are explored, which can be actuated by differential heating caused by externally controllable currents flowing through their conducting faces. The functionality of such actuators is uncovered and it is shown that they allow to 3D print, in one pass, simple flexible robotic structures that propel forward under step‐wise applied voltages. Moreover, exploiting the thermoplasticity of the nonconducting plastic parts at elevated temperatures, it is shown that how strong driving leads to irreversible deformations—a form of 4D printing—which also enlarges the range of linear response of the actuators. Finally, it is shown that how to leverage such thermoplastic relaxations to accumulate plastic deformations and obtain very large deformations by alternatively driving both layers of a bilayer; this is called ratcheting. The strategy is scalable and widely applicable, and opens up a new approach to reversible actuation and irreversible 4D printing of arbitrary structures and machines.     

3D Printed Template-Assisted Casting of Biocompatible Polyvinyl Alcohol-Based Soft Microswimmers with Tunable Stability

The past decade has seen an upsurge in the development of small-scale magnetic robots for various biomedical applications. However, many of the reported designs comprise components with biocompatibility concerns. Strategies for fabricating biocompatible and degradable microrobots are required. In this study, polyvinyl alcohol (PVA)-based magnetic hydrogel microrobots with different morphologies and tunable stability are developed by combining a 3D printed template-assisted casting with a salting-out process. 3D sacrificial micromolds are prepared via direct laser writing to shape PVA-magnetic nanoparticle composite hydrogel microrobots with high architectural complexity. By adjusting the PVA composition and salting-out parameters, the hydrogel dissolubility can be customized. Due to their high mobility, tunable stability, and high biocompatibility, these PVA-based magnetic microrobots are suitable platforms for targeted drug and cell delivery.     

3D Printed High‐Loading Lithium‐Sulfur Battery Toward Wearable Energy Storage

Wearable electronic devices are the new darling of consumer electronics, and energy storage devices are an important part of them. Here, a wearable lithium‐sulfur (Li‐S) bracelet battery using three‐dimensional (3D) printing technology (additive manufacturing) is designed and manufactured for the first time. The bracelet battery can be easily worn to power the wearable device. The “additive” manufacturing characteristic of 3D printing provides excellent controllability of the electrode thickness with much simplified process in a cost‐effective manner. Due to the conductive 3D skeleton providing interpenetrating transmission paths and channels for electrons and ions, the 3D Li‐S battery can provide 505.4 mAh g^?1 specific capacity after 500 cycles with an active material loading as high as 10.2 mg cm^?1. The practicality is illustrated by wearing the bracelet battery on the wrist and illuminating the red light‐emitting diode. Therefore, the bracelet battery manufactured by 3D printing technology can address the needs of the wearable power supply.     

3D Printed Anatomical Nerve Regeneration Pathways

A 3D printing methodology for the design, optimization, and fabrication of a custom nerve repair technology for the regeneration of complex peripheral nerve injuries containing bifurcating sensory and motor nerve pathways is introduced. The custom scaffolds are deterministically fabricated via a microextrusion printing principle using 3D models, which are reverse engineered from patient anatomies by 3D scanning. The bifurcating pathways are augmented with 3D printed biomimetic physical cues (microgrooves) and path‐specific biochemical cues (spatially controlled multicomponent gradients). In vitro studies reveal that 3D printed physical and biochemical cues provide axonal guidance and chemotractant/chemokinetic functionality. In vivo studies examining the regeneration of bifurcated injuries across a 10 mm complex nerve gap in rats showed that the 3D printed scaffolds achieved successful regeneration of complex nerve injuries, resulting in enhanced functional return of the regenerated nerve. This approach suggests the potential of 3D printing toward advancing tissue regeneration in terms of: (1) the customization of scaffold geometries to match inherent tissue anatomies; (2) the integration of biomanufacturing approaches with computational modeling for design, analysis, and optimization; and (3) the enhancement of device properties with spatially controlled physical and biochemical functionalities, all enabled by the same 3D printing process.     

太赫兹3D打印透镜综述

太赫兹波由于其独特的电磁特性可应用于超高速率无线通信、生物化学物质检测以及高分辨率成像等领域。但由于太赫兹波的物理波长小,传统适用于低频的加工工艺难以满足其加工精度的要求;而微纳米加工工艺又具有加工复杂、成本高等缺点。3D打印技术的发展为太赫兹器件的加工提供了新的选择和更多的设计灵活度。文章介绍了香港城市大学太赫兹与毫米波国家重点实验室在3D打印太赫兹透镜方面的最新研究动态和实验研究新成果,包括基于3D打印的太赫兹高增益圆极化透镜、近场聚焦圆极化透镜、贝塞尔波束生成透镜的设计,高精度3D打印方法的探索以及太赫兹天线测试方法等。太赫兹3D打印透镜天线具有低成本、低损耗、能快速成型等特点,可应用于不同的太赫兹场景中。     

Fast‐Response,Stiffness‐Tunable Soft Actuator by Hybrid Multimaterial 3D Printing

Soft robots have the appealing advantages of being highly flexible and adaptive to complex environments. However, the low‐stiffness nature of the constituent materials makes soft robotic systems incompetent in tasks requiring relatively high load capacity. Despite recent attempts to develop stiffness‐tunable soft actuators by employing variable stiffness materials and structures, the reported stiffness‐tunable actuators generally suffer from limitations including slow responses, small deformations, and difficulties in fabrication with microfeatures. This work presents a paradigm to design and manufacture fast‐response, stiffness‐tunable (FRST) soft actuators via hybrid multimaterial 3D printing. The integration of a shape memory polymer layer into the fully printed actuator body enhances its stiffness by up to 120 times without sacrificing flexibility and adaptivity. The printed Joule‐heating circuit and fluidic cooling microchannel enable fast heating and cooling rates and allow the FRST actuator to complete a softening–stiffening cycle within 32 s. Numerical simulations are used to optimize the load capacity and thermal rates. The high load capacity and shape adaptivity of the FRST actuator are finally demonstrated by a robotic gripper with three FRST actuators that can grasp and lift objects with arbitrary shapes and various weights spanning from less than 10 g to up to 1.5 kg.     

3D Printed Graphene-Based 3000 K Probe

High-temperature heating is ubiquitously utilized in material synthesis and manufacturing, which often features a rapid production rate due to the significantly improved kinetics. However, current technologies generally provide overall and steady-state heating, thereby limiting their applications in micro/nano-manufacturing that require selective patterning and swift heating. Herein, significantly improved control over small-scale heating is reported by utilizing 3D printed reduced-graphene-oxide (RGO) probe triggered by electrical Joule heating, which enables precise heating with high spatial (sub-millimeter scale) and temporal (milliseconds) resolutions. The block copolymer-modified aqueous-based RGO ink enabled 3D printing of high-precision structures, and a bio-inspired cellular microstructure is constructed to achieve control of the electrical conductivity and maximize structure robustness (benefit for efficient heating and operability). In particular, a thermal probe featuring a microscale tip with excellent heating capabilities (up to ≈3000 K, ultra-fast ramping rate of ≈10⁵ K s⁻¹, and durations in milliseconds) is fabricated. This thermal probe is ideal for surface patterning, as it is demonstrated for the selective synthesis of patterned metal (i.e., platinum and silver) nanoparticles on nano-carbon substrates, which is not possible by traditional steady-state heating. The material construction and heating strategy can be readily extended to a range of applications requiring precise control on high-temperature heating.     

Tailoring 3D Printed Micro-Structured Carbons for Adsorption

The manufacture of tailored carbon-based adsorbent structures with exceptionally low-pressure drops and improved kinetics using stereolithographic 3D printing is presented. Adsorbent structures are printed from commercial resins with square, circular, and hexagonal cross-sectional microchannels. These structures can reduce energy use by 50–95% compared to conventional carbon-packed beds. The activated 3D printed carbon achieves Brunauer–Emmett–Teller surface areas over 1000 m² g⁻¹ and shows outstanding butane adsorption capacities, over twice the capacity of a commercial carbon and a comparable capacity to phenolic-based carbons. The structures also show excellent uptakes of cyclohexane, up to 0.62 g g⁻¹ in a saturated feed. The introduction of complex axial geometries including spirals and chevrons enable superior adsorption kinetics and premature breakthrough of contaminants at high gas flow rates. These results demonstrate the success of intelligent manufacturing of low-pressure drop, high-capacity micro-structured adsorbents, allowing for the development of gas separation technologies for applications such as greenhouse gas removal and respiratory protection.     

3D Printed Supercapacitor: Techniques,Materials, Designs,and Applications

Supercapacitors (SCs) offer broad possibilities in the rising domain of military and civilian owing to their intrinsic properties of superior power density, long lifetime, and safety features. Despite of low-cost, facile manufacture, and time-saving, 3D printing technology unleashes the potential of SCs in terms of achieving desirable capacitance with high mass loading, fabrication of well-designed complicated structures, and direct construction of on-chip integration systems. In this review, first, the representative printing technologies for SCs and advanced printable materials are scrutinized for SCs and advanced printable materials. Then the structure design principles of electrodes and devices are respectively highlighted and reported cases are systematically summarized. Next, configurations of the SCs and their applications in various areas are described in detail. Finally, the promising research directions for the future are discussed. The perspectives reviewed here are expected to provide a comprehensive understanding of 3D-printed SCs and guidance in realizing their promise in various applications.     

3D打印氧化锆材料在红外探测器中的应用探索

杜瓦为红外焦平面探测器提供良好的低温工作环境以及光、机、电、热传输通道。其中冷台面支撑结构作为红外探测器的承载平台,承受设备运输、振动、冲击等作用,对支撑结构的强度提出了更高的要求。因此需要开发新型支撑结构以提高杜瓦的可靠性。根据红外探测器组件低传导漏热、高可靠性的需求,从宏观和微观的角度对不同的支撑结构材料进行分析,对比了两种成型工艺所制备的支撑结构对红外探测器设计制造的影响。与传统加工方式相比,采用数字光处理(Digital Light Procession, DLP)技术成型的氧化锆精度可达到±0.03 mm,与X射线衍射仪(X-Ray Diffractometer, XRD)衍射峰标准卡片符合。这说明其纯度较高,且该技术能缩短工艺时长,优化封装流程。     

3D Printed Enzyme-Functionalized Scaffold Facilitates Diabetic Bone Regeneration

Patients with diabetes mellitus (DM) suffer from a high risk of fractures and poor bone healing ability. Surprisingly, no effective therapy is available to treat diabetic bone defect in clinic. Here, a 3D printed enzyme-functionalized scaffold with multiple bioactivities including osteogenesis, angiogenesis, and anti-inflammation in diabetic conditions is proposed. The as-prepared multifunctional scaffold is constituted with alginate, glucose oxidase (GOx), and catalase-assisted biomineralized calcium phosphate nanosheets (CaP@CAT NSs). The GOx inside scaffolds can alleviate the hyperglycemia environment by catalyzing glucose and oxygen into gluconic acid and hydrogen peroxide (H₂O₂). Both the generated H₂O₂ as well as the overproduced H₂O₂ in DM can be scavenged by CaP@CAT NSs, while the initiated hypoxic microenvironment stimulates neovascularization. Moreover, the incorporation of CaP@CAT NSs not only enhance the mechanical property of the scaffolds, but also facilitate bone regeneration by the degraded Ca²⁺ and PO₄³⁻ ions. The remarkable in vitro and in vivo outcomes demonstrate that enzymes functionalized scaffolds can be an effective strategy for enhancing bone tissue regeneration in diabetic conditions, underpinning the potential of multifunctional scaffolds for diabetic bone regeneration.     

A Personalized Multifunctional 3D Printed Shape Memory-Displaying,Drug Releasing Tracheal Stent

The ability to engineer custom-made medical devices and to implant them minimally invasively are two important trends in modern surgery. The personalization of the device is achieved by 3D printing it, while the capacity to deploy it minimally invasively harnesses the shape memory behavior displayed by the inks used. This study introduces a 3D printed, shape memory-displaying tracheal stent based on novel, flexible photo-polymerizable inks comprising polypropylene glycol/polycaprolactone triblocks. This research introduces the in situ welding strategy, whereby thin and flexible layers of the stent are separately printed, sequentially deployed, and then welded together at the tracheal site. By doing so, the insertion profile of the device is dramatically reduced and its flexibility largely increased. Porous stents are 3D printed seeking to prevent mucus plugging. By combining more than one ink, their properties are further fine-tuned. Polyethylene glycol chains are covalently bonded to the stent surface to minimize biofilm formation, an important drawback of current tracheal stents. The in vitro cell viability and cell adhesion behavior of the treated surfaces reveal their compatibility and anti-adhesive behavior. In order to prevent implant-related infections, ciprofloxacin is added to the ink, and released in vitro over time, rendering the stent with antibacterial activity.     

3D Printing of Liquid Metals: Recent Advancements and Challenges

The development of flexible electronics (FEs) has rapidly accelerated in numerous fields due to their exceptional deformability, bending, and stretchability. Room-temperature gallium-based liquid metals (LMs) are considered as efficient conductive materials for FEs due to their outstanding electrical conductivity and intrinsic flexibility. Recently, 3D printing has become a promising technique for fabricating FEs. However, the poor printability due to high surface tension and fluidity offers huge challenges in the 3D printing of LMs. This review summarizes the effective strategies to address these challenges. It primarily focuses on three points: 1) how to improve the printability of LM and its wettability with the substrate, 2) how to select the appropriate printing method to improve the printing speed and ensure the resolution of printing structure, and 3) how to provide perfect encapsulation for LM-based FEs with 3D printing. Following a brief introduction, the mainstream printing technologies and recent developments in the 3D printing of LMs are provided, with an emphasis on the selection of printing method, improvement of printability, encapsulation, and conductivity activation. Then, the revolutionary changes attained after 3D printing of LMs are specifically focused upon. Finally, opinions and potential directions for this thriving discipline are explored.     

A Hierarchical 3D Graft Printed with Nanoink for Functional Craniofacial Bone Restoration

An ideal craniofacial bone repair graft shall not only focus on the repair ability but also the regeneration of natural architecture with occlusal loads-related function restoration. However, such functional bone tissue engineering scaffold has rarely been reported. Herein, a hierarchical 3D graft is proposed for rebuilding craniofacial bone with both natural structure and healthy biofunction reconstruction. Inspired by the bone healing process, an organic–inorganic nanoink with ultrasmall calcium phosphate oligomers and bone morphogenetic protein-2 incorporated is developed for spatiotemporal guidance of new bone. Based on such homogeneous nanoink, a biomimetic graft, including a cortical layer containing Haversian system, and a cancellous layer featured with triply periodic minimum surface macrostructures, is fabricated via projection-based 3D printing method, and the layers are loaded with distinct concentrations of bioactive factors for regenerating new bone with gradient density. The graft exhibits excellent osteogenic and angiogenic potential in vitro, and accelerates revascularization and reconstructs neo-bone with original morphology in vivo. Benefiting from such natural architecture, loading force is widely transferred with reduced stress concentration around the inserted dental implant. Taken from native physiochemical and structural cues, this wstudy provides a novel strategy for functional tissue engineering through designing function-oriented biomaterials.     

3D Printed Nanocarbon Frameworks for Li-Ion Battery Cathodes

The use of conductive carbon materials in 3D-printing is attracting growing academic and industrial attention in electrochemical energy storage due to the high customization and on-demand capabilities of the additive manufacturing. However, typical polymers used in conductive filaments for 3D printing show high resistivity and low compatibility with electrochemical energy applications. Removal of insulating thermoplastics in as-printed materials is a common post-printing strategy, however, excessive loss of thermoplastics can weaken the structural integrity. This work reports a two-step surface engineering methodology for fabrication of 3D-printed carbon materials for electrochemical applications, incorporating conductive poly(ortho-phenylenediamine) (PoPD) via electrodeposition. A conductive PoPD effectively enhances the electrochemical activities of 3D-printed frameworks. When PoPD-refilled frameworks casted with LiMn₂O₄ (LMO) composite materials used as battery cathode, it delivers a capacity of 69.1 mAh g⁻¹ at a current density of 0.036 mA cm⁻² ( ≈ 1.2 C discharge rate) and good cyclability with a retained capacity of 84.4% after 200 cycles at 0.36 mA cm⁻². This work provides a pathway for developing electroactive 3D-printed electrodes particularly with cost-efficient low-dimensional carbon materials for aqueous rechargeable Li-ion batteries.     

Wood‐Inspired 3D‐Printed Helical Composites with Tunable and Enhanced Mechanical Performance

Helical fibers are versatile building blocks used by Nature to improve mechanical performance and to tune local behavior of load‐bearing materials. Helicoidal biocomposites are arranged in multiple layers with different fiber orientations. Such heterogeneity, not matched in synthetic materials, provides biological structures with superior properties. This is the case of the multilayer tube‐like structure of the wood cell wall, where each ply features a compliant matrix reinforced by stiff helicoidal microfibrils. Here, 3D polyjet printing and computer simulations are combined to investigate wood‐inspired helix‐reinforced cylinders. Composites with a main layer containing helicoidal fibers, bordered by inner and outer plies having thinner fibrils are considered. It is shown how the mechanical functionalities of the synthetic structures can be programmed by varying fibers/fibrils orientation and matrix compliance. It is demonstrated that failure resistance can be enhanced by enclosing the main helicoidal layer with a minimum amount of thin fibrils oriented perpendicular to the applied load, as observed in wood. Finite element simulations are used to highlight the critical role of the matrix in load‐transfer mechanisms among stiff elements. These structures have the potential to be assembled into larger systems, leading to graded composites with region‐specific properties optimized for multiple functionalities.