3D Conformal Printing and Photonic Sintering of High‐Performance Flexible Thermoelectric Films Using 2D Nanoplates

Flexible thermoelectric (TE) devices hold great promise for energy harvesting and cooling applications, with increasing significance to serve as perpetual power sources for flexible electronics and wearable devices. Despite unique and superior TE properties widely reported in nanocrystals, transforming these nanocrystals into flexible and functional forms remains a major challenge. Herein, demonstrated is a transformative 3D conformal aerosol jet printing and rapid photonic sintering process to print and sinter solution‐processed Bi₂Te_2.7Se_0.3 nanoplate inks onto virtually any flexible substrates. Within seconds of photonic sintering, the electrical conductivity of the printed film is dramatically improved from nonconductive to 2.7 × 10⁴ S m^?1. The films demonstrate a room temperature power factor of 730 µW m^?1 K^?2, which is among the highest values reported in flexible TE films. Additionally, the film shows negligible performance changes after 500 bending cycles. The highly scalable and low‐cost fabrication process paves the way for large‐scale manufacturing of flexible devices using a variety of high‐performing nanoparticle inks.     

3D Printing of Hydrogels for Stretchable Ionotronic Devices

In the booming development of flexible electronics represented by electronic skins, soft robots, and human–machine interfaces, 3D printing of hydrogels, an approach used by the biofabrication community, is drawing attention from researchers working on hydrogel-based stretchable ionotronic devices. Such devices can greatly benefit from the excellent patterning capability of 3D printing in three dimensions, as well as the free design complexity and easy upscale potential. Compared to the advanced stage of 3D bioprinting, 3D printing of hydrogel ionotronic devices is in its infancy due to the difficulty in balancing printability, ionic conductivity, shape fidelity, stretchability, and other functionalities. In this review, a guideline is provided on how to utilize the power of 3D printing in building high-performance hydrogel-based stretchable ionotronic devices mainly from a materials’ point of view, highlighting the systematic approach to balancing the printability, printing quality, and performance of printed devices. Various 3D printing methods for hydrogels are introduced, and then the ink design principles, balancing printing quality, printed functions, such as elastic conductivity, self-healing ability, and device (e.g., flexible sensors, shape-morphing actuators, soft robots, electroluminescent devices, and electrochemical biosensors) performances are discussed. In conclusion, perspectives on the future directions of this exciting field are presented.     

Seriography‐Guided Reduction of Graphene Oxide Biopapers for Wearable Sensory Electronics

Novel nacre‐mimic bio‐nanocomposites, such as graphene‐based laminates, are pushing the boundaries of strength and toughness as flexible engineering materials. Translating these material advances to functional flexible electronics requires methods for generating print‐scalable microcircuits (conductive elements surrounded by dielectric) into these strong, tough, lightweight bio‐nanocomposites. Here, a new paradigm for printing flexible electronics by employing facile, eco‐friendly seriography to confine the reduction of graphene oxide biopapers reinforced by silk interlayers is presented. Well‐defined, micropatterned regions on the biopaper are chemically reduced, generating a 10⁶ increase in conductivity (up to 10⁴ S m^?1). Flexible, robust graphene‐silk circuits are showcased in diverse applications such as resistive moisture sensors and capacitive proximity sensors. Unlike conductive (i.e., graphene‐ or Ag nanoparticle‐loaded) inks printed onto substrates, seriography‐guided reduction does not create mechanically weak interfaces between dissimilar materials and does not require the judicious formation of ink. The unimpaired functionality of printed‐in graphene‐silk microcircuits after thousands of punitive folding cycles and chemical attack by harsh solvents is demonstrated. This novel approach provides a low‐cost, portable solution for printing micrometer‐scale conductive features uniformly across large areas (>hundreds of cm²) in layered composites for applications including wearable health monitors, electronic skin, rollable antennas, and conformable displays.     

Conductive Screen Printing Inks by Gelation of Graphene Dispersions

This paper describes the gelation of highly concentrated graphene/polymer dispersions triggered by mild heating. The gel formation is only dependent on the concentration of graphene with 3.25 mg mL^?1 as the minimum value for graphene network formation. The graphene gel is then utilized for the preparation of colloidally stable and highly concentrated (52 mg mL^?1) graphene pastes that demonstrate excellent performance in screen printing down to lines of 40 μm in width. Printed patterns dried at 100 °C for only 5 min exhibit sheet resistances of 30 Ω ^?1 at 25 μm thickness, thus, removing the need for long‐time high temperature annealing, doping, or other treatments. Such a low drying temperature, high printing definition, and compatibility with industrially relevant plastic and paper substrates brings high‐volume roll‐to‐roll application in printed flexible electronics within reach.     

Delamination‐Free Functional Graphene Surface by Multiscale,Conformal Wrinkling

Obtaining a delamination‐free wrinkled functional graphene surface in layered systems is an interesting challenge because the interface is usually too weak to withstand interfacial stress mismatch, which can trigger mechanical instability. In this paper, a general strategy is proposed toward addressing the delamination limitation imposed by fabricating conformal graphene wrinkles with bilayer systems of poly(methyl methacrylate) (PMMA) and polydimethylsiloxane (PDMS). To improve the interfacial strength, a postcuring transfer process is introduced to form a gradient interface layer without interfacial liquid between the PMMA and PDMS by entanglement of polymer chains during high‐temperature curing. Compared to the conventional wet transfer of graphene,the transfer method can greatly enhance the interfacial strength. The chemical and mechanical mechanisms underlying the enhancement are revealed both experimentally and theoretically in terms of the transition from the buckled‐induced delamination state to the delamination‐free wrinkled state. Moreover, the light diffraction behaviors of multiscale graphene wrinkles are initially demonstrated to be an interesting continuous pattern induced by overlapping. The delamination‐free conformal wrinkled functional graphene surface can provide valuable insight and design guidelines for the fundamental problems of deformed graphene and its applications in flexible functional devices.     

Direct 3D Printing of Ultralight Graphene Oxide Aerogel Microlattices

Graphene aerogel microlattices (GAMs) hold great prospects for many multifunctional applications due to their low density, high porosity, designed lattice structures, good elasticity, and tunable electrical conductivity. Previous 3D printing approaches to fabricate GAMs require either high content of additives or complex processes, limiting their wide applications. Here, a facile ion‐induced gelation method is demonstrated to directly print GAMs from graphene oxide (GO) based ink. With trace addition of Ca²⁺ ions as gelators, aqueous GO sol converts to printable gel ink. Self‐standing 3D structures with programmable microlattices are directly printed just in air at room temperature. The rich hierarchical pores and high electrical conductivity of GAMs bring admirable capacitive performance for supercapacitors. The gravimetric capacitance (C_s) of GAMs is 213 F g^?1 at 0.5 A g^?1 and 183 F g^?1 at 100 A g^?1, and retains over 90% after 50 000 cycles. The facile, direct 3D printing of neat graphene oxide can promote wide applications of GAMs from energy storage to tissue engineering scaffolds.     

Simplified Large‐Area Manufacturing of Organic Electrochemical Transistors Combining Printing and a Self‐Aligning Laser Ablation Step

A hybrid manufacturing approach for organic electrochemical transistors (OECTs) on flexible substrates is reported. The technology is based on conventional and digital printing (screen and inkjet printing), laser processing, and post‐press technologies. A careful selection of the conductive, dielectric, and semiconductor materials with respect to their optical properties enables a self‐aligning pattern formation which results in a significant reduction of the usual registration problems during manufacturing. For the prototype OECTs, based on this technology, on/off ratios up to 600 and switching times of 100 milliseconds at gate voltages in the range of 1 V were obtained.     

Graphene Oxide Based Transparent Resins For Accurate 3D Printing of Conductive Materials

Digital Light Processing (DLP) allows the fast realization of 3D objects with high spatial resolution. However, DLP is limited to transparent resins, and therefore not well suited for printing electrically conductive materials. Manufacturing conductive materials will significantly broaden the spectrum of applications of the DLP technology. But conductive metals or carbon-based fillers absorb and scatter light; inhibiting thereby photopolymerization, and lowering resolution. In this study, UV transparent liquid crystal graphene oxide (GO) is used as precursor for generating in situ conductive particles. The GO materials are added to a photopolymerizable resin via an original solvent exchange process. By contrast to earlier contributions, the absence of drying during the all process allows the GO material to be transferred as monolayers to limit UV scattering. The absence of UV scattering and absorption allows for fast and high-resolution 3D printing. The chosen resin sustain high temperature to enable an in situ efficient thermal reduction of GO into reduced graphene oxide (rGO) that is electrically conductive. The rGO particles form percolated networks with conductivities up to 1.2 × 10⁻² S m⁻¹. The present method appears therefore as a way to reconcile the DLP technology with the manufacturing of 3D electrically conductive objects.     

Helical 3D‐Printed Metal Electrodes as Custom‐Shaped 3D Platform for Electrochemical Devices

3D‐printing represents an emerging technology that can revolutionize the way object and functional devices are fabricated. Here the use of metal 3D printing is demonstrated to fabricate bespoke electrochemical stainless steel electrodes that can be used as platform for different electrochemical applications ranging from electrochemical capacitors, oxygen evolution catalyst, and pH sensor by means of an effective and controlled deposition of IrO₂ films. The electrodes have been characterized by scanning electrode microscopy and energy dispersive X‐ray spectroscopy before the electrochemical testing. Excellent pseudocapacitive as well as catalytic properties have been achieved with these 3D printed steel‐IrO₂ electrodes in alkaline solutions. These electrodes also demonstrate Nernstian behavior as pH sensor. This work represents a breakthrough in on‐site prototyping and fabrication of highly tailored electrochemical devices with complex 3D shapes which facilitate specific functions and properties.     

3D Micro‐Extrusion of Graphene‐based Active Electrodes: Towards High‐Rate AC Line Filtering Performance Electrochemical Capacitors

A facile one‐step printing process by 3D micro‐extrusion affording binder‐free thermally reduced graphene oxide (TRGO) based electrochemical capacitors (ECs) that display high‐rate performance is presented. Key intermediates are binder‐free TRGO dispersion printing inks with concentrations up to 15 g L^?1. This versatile printing technique enables easy fabrication of EC electrodes, useful in both aqueous and non‐aqueous electrolyte systems. The as‐prepared TRGO material with high specific surface area (SSA) of 593 m² g^?1 and good electrical conductivity of ≈16 S cm^?1 exhibits impressive charge storage performances. At 100 and 120 Hz, ECs fabricated with TRGO show time constants of 2.5 ms and 2.3 ms respectively. Very high capacitance values are derived at both frequencies ranging from 3.55 mF cm^?2 to 1.76 mF cm^?2. Additionally, these TRGO electrodes can be charged and discharged at very high voltage scan rates up to 15 V s^?1 yielding 4 F cm^?3 with 50% capacitance retention. Electrochemical performance of TRGO electrodes in electrolyte containing tetraethyl ammonium tetrafluoroborate and acetonitrile (TEABF4‐ACN) yields high energy density of 4.43 mWh cm^?3 and power density up to 42.74 kW cm^?3, which is very promising for AC line filtering application and could potentially substitute state of the art electrolytic capacitor technology.     

Scalable Production of Graphene Inks via Wet‐Jet Milling Exfoliation for Screen‐Printed Micro‐Supercapacitors

The miniaturization of energy storage units is pivotal for the development of next‐generation portable electronic devices. Micro‐supercapacitors (MSCs) hold great potential to work as on‐chip micro‐power sources and energy storage units complementing batteries and energy harvester systems. Scalable production of supercapacitor materials with cost‐effective and high‐throughput processing methods is crucial for the widespread application of MSCs. Here, wet‐jet milling exfoliation of graphite is reported to scale up the production of graphene as a supercapacitor material. The formulation of aqueous/alcohol‐based graphene inks allows metal‐free, flexible MSCs to be screen‐printed. These MSCs exhibit areal capacitance (C_areal) values up to 1.324 mF cm^?2 (5.296 mF cm^?2 for a single electrode), corresponding to an outstanding volumetric capacitance (C_vol) of 0.490 F cm^?3 (1.961 F cm^?3 for a single electrode). The screen‐printed MSCs can operate up to a power density above 20 mW cm^?2 at an energy density of 0.064 µWh cm^?2. The devices exhibit excellent cycling stability over charge–discharge cycling (10 000 cycles), bending cycling (100 cycles at a bending radius of 1 cm) and folding (up to angles of 180°). Moreover, ethylene vinyl acetate‐encapsulated MSCs retain their electrochemical properties after a home‐laundry cycle, providing waterproof and washable properties for prospective application in wearable electronics.     

Emulsifier‐Free Graphene Dispersions with High Graphene Content for Printed Electronics and Freestanding Graphene Films

A novel and highly versatile synthetic route for the production of functionalized graphene dispersions in water, acetone, and isopropanol (IPA), which exhibit long‐term stability and are easy to scale up, is reported. Both graphene functionalization (wherein the oxygen content can be varied from 4 to 16 wt%) and dispersion are achieved by the thermal reduction of graphite oxide, followed by a high‐pressure homogenization (HPH) process. For the first time, binders, dispersing agents, and reducing agents are not required to produce either dilute or highly concentrated dispersions of single graphene sheets with a graphene content of up to 15 g L^?1. High graphene content is essential for the successful printing of graphene dispersions by 3D microextrusion. Free‐standing graphene films and micropatterned graphene materials are successfully prepared using this method. Due to the absence of toxic reducing agents, the graphene exhibits no cytotoxicity and is biocompatible. Furthermore, the electrical conductivity of graphene is significantly improved by the absence of binders. Flexible microarrays can be printed on different substrates, producing microarrays that are mechanically stable and can be bent several times without affecting electrical conductivity.     

Functionalized Graphene Superlattice as a Single‐Sheet Solar Cell

In‐plane heterostructure engineering provides unique opportunities to control device properties. Here, a single‐sheet solar cell made of a graphene sheet functionalized into 1D channels is explored. Compared to vertical heterostructure architectures based on 2D materials, the single‐sheet solar cell shows potential for improved robustness against defects, enhancement of polaron dissociation, extra freedom for functionalization, and coverage of the entire solar spectrum. The partition width, device length, and functionalizations can be tuned independently to optimize the key optoelectronic properties for photovoltaic performance.     

Particle‐Free Emulsions for 3D Printing Elastomers

3D printing is a rapidly growing field that requires the development of yield‐stress fluids that can be used in postprinting transformation processes. There is a limited number of yield‐stress fluids currently available with the desired rheological properties for building structures with small filaments (≤l00 µm) with high shape‐retention. A printing‐centric approach for 3D printing particle‐free silicone oil‐in‐water emulsions with a polymer additive, poly(ethylene oxide) is presented. This particular material structure and formulation is used to build 3D structure and to pattern at filament diameters below that of any other known material in this class. Increasing the molecular weight of poly(ethylene oxide) drastically increases the extensibility of the material without significantly affecting shear flow properties (shear yield stress and linear viscoelastic moduli). Higher extensibility of the emulsion correlates to the ability of filaments to span relatively large gaps (greater than 6 mm) when extruded at large tip diameters (330 µm) and the ability to extrude filaments at high print rates (20 mm s^?1). 3D printed structures with these extensible particle‐free emulsions undergo postprinting transformation, which converts them into elastomers. These elastomers can buckle and recover from extreme compressive strain with no permanent deformation, a characteristic not native to the emulsion.     

Coaxial 4D Printing of Vein-Inspired Thermoresponsive Channel Hydrogel Actuators

Although significant progress has been made in coaxial printing of vascularized tissue models, this technique has not yet been used to fabricate stimulus-responsive scaffolds capable of shape change over time. Here, a new method of direct ink printing (DIP) is proposed with a coaxial nozzle, coaxial 4D printing, enabling the manufacturing of thermoresponsive constructs embedded with a network of interconnected channels. In this approach, a poly(N-isopropylacrylamide) (PNIPAAm)-based thermoink is coaxially extruded into either core/sheath microfibers or microtubes. PNIPAAm renders a hydrogel temperature-sensitive and endows it with a shape-morphing property both at the micro- and macroscale. Specifically, the lumen diameter of the microtubes can be controlled by temperature by 30%. The macrostructural soft actuators can undergo programmed and reversible temperature-dependent shape changes due to the structural anisotropy of the hydrogel. The permeability tests demonstrate that the hydrogel can possess enough strength to maintain the hollow channels without breaking. In vitro tests confirm the biocompatibility of the material with EA.hy926 cells, paving the avenue for new perfusable soft robots, or active implants. Finally, microalgae Chlamydomonas reinhardtii is combined with the hydrogels to fabricate materials having functions of both living microorganisms and stimuli-responsive polymers toward creating engineered living materials (ELMs) with a vein-like geometry.     

A Self-Thickening and Self-Strengthening Strategy for 3D Printing High-Strength and Antiswelling Supramolecular Polymer Hydrogels as Meniscus Substitutes

3D printing of high-strength and antiswelling hydrogel-based load-bearing soft tissue scaffolds with similar geometric shape to natural tissues remains a great challenge owing to insurmountable trade-off between strength and printability. Herein, capitalizing on the concentration-dependent H-bonding-strengthened mechanism of supramolecular poly(N-acryloyl glycinamide) (PNAGA) hydrogel, a self-thickening and self-strengthening strategy, that is, loading the concentrated NAGA monomer into the thermoreversible low-strength PNAGA hydrogel is proposed to directly 3D printing latently H-bonding-reinforced hydrogels. The low-strength PNAGA serves to thicken the concentrated NAGA monomer, affording an appropriate viscosity for thermal-assisted extrusion 3D printing of soft PNAGA hydrogels bearing NAGA monomer and initiator, which are further polymerized to eventually generate high-strength and antiswelling hydrogels, due to the reconstruction of strong H-bonding interactions from postcompensatory PNAGA. Diverse polymer hydrogels can be printed with self-thickened corresponding monomer inks. Further, the self-thickened high-strength PNAGA hydrogel is printed into a meniscus, which is implanted in rabbit's knee as a substitute with in vivo outcome showing an appealing ability to efficiently alleviate the cartilage surface wear. The self-thickening strategy is applicable to directly printing a variety of polymer-hydrogel-based tissue engineering scaffolds without sacrificing mechanical strength, thus circumventing problems of printing high-strength hydrogels and facilitating their application scope.     

Paper with Power: Engraving 2D Materials on 3D Structures for Printed,High‐Performance,Binder‐Free,and All‐Solid‐State Supercapacitors

The prevalence of the Internet of Things (IoT) and wearable electronics create an unprecedented demand for new power sources which are low cost, high performance, and flexible in many application settings. In this paper, a strategy for the scalable fabrication of high‐performance, all‐solid‐state supercapacitors (SCs) is demonstrated using conventional paper and an inkjet printer. Emerging printed electronics technology and low‐cost chemical engraving methods are bridged for the first time to construct Cu_xO nanosheets, in situ, on the 3D metallized fiber structures. Benefitting from both the “2D Materials on 3D Structures” design and the binder‐free nature of the fabricated electrodes, substantial improvements to electrical conductivity, aerial capacitance, and electrochemical performance of the resulting SCs are observed. With the proposed strategy, the fabricated SCs can be seamlessly integrated into any printed circuit, sensors, or artwork; the properties of these SCs can be easily tuned by simple pattern design, fulfilling the increasing demand of highly customized power systems in the IoT and flexible/wearable electronics industries.     

Multifunctional Artificial Artery from Direct 3D Printing with Built‐In Ferroelectricity and Tissue‐Matching Modulus for Real‐Time Sensing and Occlusion Monitoring

Treating vascular grafts failure requires complex surgery procedures and is associated with high risks. A real‐time monitoring vascular system enables quick and reliable identification of complications and initiates safer treatments early. Here, an electric fieldassisted 3D printing technology is developed to fabricate in situ‐poled ferroelectric artificial arteries that offer battery‐free real‐time blood pressure sensing and occlusion monitoring capability. The functional artery architecture is made possible by the development of a ferroelectric biocomposite which can be quickly polarized during printing and reshaped into devised objects. The synergistic effect from the potassium sodium niobite particles and the polyvinylidene fluoride polymer matrix yields a superb piezoelectric performance (bulk‐scale d₃₃ > 12 pC N^?1). The sinusoidal architecture brings the mechanical modulus close to the level of blood vessels. The desired piezoelectric and mechanical properties of the artificial artery provide an excellent sensitivity to pressure change (0.306 mV mmHg^?1, R² > 0.99) within the range of human blood pressure (11.25–225.00 mmHg). The high pressure sensitivity and the ability to detect subtle vessel motion pattern change enable early detection of partial occlusion (e.g., thrombosis), allowing for preventing grafts failure. This work demonstrates a promising strategy of incorporating multifunctionality to artificial biological systems for smart healthcare systems.     

Oxidation‐Resistant and Elastic Mesoporous Carbon with Single‐Layer Graphene Walls

An oxidation‐resistant and elastic mesoporous carbon, graphene mesosponge (GMS), is prepared. GMS has a sponge‐like mesoporous framework (mean pore size is 5.8 nm) consisting mostly of single‐layer graphene walls, which realizes a high electric conductivity and a large surface area (1940 m² g^?1). Moreover, the graphene‐based framework includes only a very small amount of edge sites, thereby achieving much higher stability against oxidation than conventional porous carbons such as carbon blacks and activated carbons. Thus, GMS can simultaneously possess seemingly incompatible properties; the advantages of graphitized carbon materials (high conductivity and high oxidation resistance) and porous carbons (large surface area). These unique features allow GMS to exhibit a sufficient capacitance (125 F g^?1), wide potential window (4 V), and good rate capability as an electrode material for electric double‐layer capacitors utilizing an organic electrolyte. Hence, GMS achieves a high energy density of 59.3 Wh kg^?1 (material mass base), which is more than twice that of commercial materials. Moreover, the continuous graphene framework makes GMS mechanically tough and extremely elastic, and its mean pore size (5.8 nm) can be reversibly compressed down to 0.7 nm by simply applying mechanical force. The sponge‐like elastic property enables an advanced force‐induced adsorption control.