Mechanical Properties Tailoring of 3D Printed Photoresponsive Nanocellulose Composites

3D printing technologies allow control over the alignment of building blocks in synthetic materials, but compositional changes often require complex multimaterial printing steps. Here, 3D printable materials showing locally tunable mechanical properties are produced in a single printing step of Direct Ink Writing. These new inks consist of a polymer matrix bearing biocompatible photoreactive cinnamate derivatives and up to 30 wt% of anisotropic cellulose nanocrystals. The printed materials are mechanically versatile and can undergo further crosslinking upon illumination. When illuminating the material and controlling the irradiation doses, the Young's moduli can be adjusted between 15 and 75 MPa. Moreover, spatially controlled illumination allows patterning stiff geometries, resulting in 3D printed structures with segments of different mechanical properties tailoring the mechanical behavior under compression. The high design freedom implemented by 3D printing and photopatternability opens the venue to rapid manufacturing of devices for applications such as prosthetics or soft robotics where the 3D shapes and mechanical properties must be tailored for personalized load cases.     

Two‐Phase Emulgels for Direct Ink Writing of Skin‐Bearing Architectures

Direct ink writing (DIW) provides programmable and customizable platforms to engineer hierarchically organized constructs. However, one‐step, facile synthesis of such architectures via DIW has been challenging. This study introduces inks based on two‐phase emulgels for direct printing and in situ formation of protecting layers enveloping multicomponent cores, mimicking skin‐bearing biological systems. The emulgel consists of a Pickering emulsion with an organic, internal phase containing poly(lactic acid) stabilized by chitin/cellulose nanofibers and a continuous, cross‐linkable hydrogel containing cellulose nanofibers and any of the given solid particles. The shear during ink extrusion through nozzles of low surface energy facilitates the generation of the enveloped structures via fast and spontaneous phase separation of the emulgel. The skin‐bearing architectures enable control of mass transport as a novel configuration for cargo release. As a demonstration, a hydrophilic molecule is loaded in the hydrogel, which is released through the core and skin, enabling regulation of diffusion and permeation phenomena. This 3D‐printed functional material allows independent control of strength owing to the hierarchical construction. The new method of fabrication is proposed as a simple way to achieve protection, regulation, and sensation, taking the example of the functions of skins and cuticles, which are ubiquitous in nature.     

Engineering Natural Pollen Grains as Multifunctional 3D Printing Materials

The development of multifunctional 3D printing materials from sustainable natural resources is a high priority in additive manufacturing. Using an eco-friendly method to transform hard pollen grains into stimulus-responsive microgel particles, we engineered a pollen-derived microgel suspension that can serve as a functional reinforcement for composite hydrogel inks and as a supporting matrix for versatile freeform 3D printing systems. The pollen microgel particles enabled the printing of composite inks and improved the mechanical and physiological stabilities of alginate and hyaluronic acid hydrogel scaffolds for 3D cell culture applications. Moreover, the particles endowed the inks with stimulus-responsive controlled release properties. The suitability of the pollen microgel suspension as a supporting matrix for freeform 3D printing of alginate and silicone rubber inks was demonstrated and optimized by tuning the rheological properties of the microgel. Compared with other classes of natural materials, pollen grains have several compelling features, including natural abundance, renewability, affordability, processing ease, monodispersity, and tunable rheological features, which make them attractive candidates to engineer advanced materials for 3D printing applications.     

Printing of Responsive Photonic Cellulose Nanocrystal Microfilm Arrays

Interactive materials capable of changing appearance upon exposure to external stimuli, such as photonic inks, are generally difficult to achieve on a large scale as they often require self‐assembly processes that are difficult to control macroscopically. Here this problem is overcome by preparing arrays of cellulose nanocrystal (CNC) microfilms from discrete nanoliter sessile droplets. The obtained microfilms show extremely uniform and intense color, enabling exceptional consistency in optical appearance across the entire array. The color can be controlled through the initial ink formulation, enabling the printing of polychromatic dot‐matrix images. Moreover, the high surface‐to‐volume ratio of the microfilms and the intrinsic hydrophilicity of the natural building block allow for a dramatic real‐time colorimetric response to changes in relative humidity. The printed CNC microfilm arrays overcome the existing issues of scalability, optical uniformity, and material efficiency, which have held back the adoption of CNC‐based photonic materials in cosmetics, interactive‐pigments, or anticounterfeit applications.     

3D Printing of Multifunctional Hydrogels

3D printing technology has been widely explored for the rapid design and fabrication of hydrogels, as required by complicated soft structures and devices. Here, a new 3D printing method is presented based on the rheology modifier of Carbomer for direct ink writing of various functional hydrogels. Carbomer is shown to be highly efficient in providing ideal rheological behaviors for multifunctional hydrogel inks, including double network hydrogels, magnetic hydrogels, temperature‐sensitive hydrogels, and biogels, with a low dosage (at least 0.5% w/v) recorded. Besides the excellent printing performance, mechanical behaviors, and biocompatibility, the 3D printed multifunctional hydrogels enable various soft devices, including loadable webs, soft robots, 4D printed leaves, and hydrogel Petri dishes. Moreover, with its unprecedented capability, the Carbomer‐based 3D printing method opens new avenues for bioprinting manufacturing and integrated hydrogel devices.     

Multicolored Nanocolloidal Hydrogel Inks

Nanocolloidal gels are emerging as a promising class of materials with applications as inks in 2D and 3D printing. Polymer nanoparticles (NPs) offer many advantages as potential building blocks of nanocolloidal gels, due to the ability to control NP dimensions, charge, surface chemistry, and functionality; however, their applications as inks in printing are yet to be explored. Here, functional nanocolloidal hydrogels formed by percolating oppositely charged latex NPs with different dimensions and charge densities are reported. The shear-thinning and self-healing properties of the nanocolloidal gels and the mechanical properties of the resulting printed films are examined. NP functionality is achieved by covalently labeling them with different fluorescent dyes that emit at two distinct wavelengths. Using these NPs, a facile route for 3D printing of multicolored fluorescence patterns is shown, with each color being visualized under a specific, well-defined excitation wavelength.     

All‐Printed Flexible and Stretchable Electronics with Pressing or Freezing Activatable Liquid‐Metal–Silicone Inks

Liquid‐metal (LM)‐based flexible and stretchable electronics have attracted widespread interest in wearable computing, human–machine interaction, and soft robotics. However, many current examples are one‐off prototypes, whereas future implementation requires mass production. To address this critical challenge, an integrated multimaterial 3D printing process composed of direct ink writing (DIW) of sealing silicone elastomer and special LM‐silicone (LMS) inks for manufacturing high‐performance LM‐based flexible and stretchable electronics is presented. The LMS ink is a concentrated mixture of LM microdroplets and silicone elastomer and exhibits excellent printability for DIW printing. Guided by a verified theoretical model, a printing process with high resolution and high speed can be easily implemented. Although LMS is not initially conductive, it can be activated by pressing or freezing. Activated LMS possesses good conductivity and significant electrical response to strain. Owing to LMS's unique structure, LMS‐embedded flexible electronics exhibit great damage mitigation, in that no leaking occurs even when damaged. To demonstrate the flexibility of this process in fabricating LM‐based flexible electronics, multilayer soft circuits, strain sensors, and data gloves are printed and investigated. Notably, utilizing LMS's unique activating property, some functional circuits such as one‐time pressing/freezing‐on switch can be printed without any structural design.     

Mechanically Robust,Ultraelastic Hierarchical Foam with Tunable Properties via 3D Printing

A mechanically robust, ultraelastic foam with controlled multiscale architectures and tunable mechanical/conductive performance is fabricated via 3D printing. Hierarchical porosity, including both macro‐ and microscaled pores, are produced by the combination of direct ink writing (DIW), acid etching, and phase inversion. The thixotropic inks in DIW are formulated by a simple one‐pot process to disperse duo nanoparticles (nanoclay and silica nanoparticles) in a polyurethane suspension. The resulting lightweight foam exhibits tailorable mechanical strength, unprecedented elasticity (standing over 1000 compression cycles), and remarkable robustness (rapidly and fully recover after a load more than 20 000 times of its own weight). Surface coating of carbon nanotubes yields a conductive elastic foam that can be used as piezoresistivity sensor with high sensitivity. For the first time, this strategy achieves 3D printing of elastic foam with controlled multilevel 3D structures and mechanical/conductive properties. Moreover, the facile ink preparation method can be utilized to fabricate foams of various materials with desirable performance via 3D printing.     

Double-Interlinked Colloidal Gels for Programable Fabrication of Supraparticle Architectures

Engineering colloidal gel inks with suitable features for fabricating robust supraparticle architectures through 3D printing may overcome the challenges of precisely controlling nanoparticles spatial distribution across multiple scales. Herein, oppositely charged proteinaceous-polymeric nanoparticles are combined to generate multi-component colloidal gel (COGEL) inks for fabricating supraparticle volumetric architectures. Leveraging on different nano-functional units, double-interlinked supraparticle assemblies are established via electrostatic interactions and on-demand covalent photocrosslinking. The COGEL inks are readily processable through in-air extrusion 3D printing, forming stable colloidal filaments. 3D printing yielded architecturally defined and robust supraparticle constructs that supported human stem cells attachment and cytoskeletal spreading. Owing to double interparticle interlinks the fabricated supraparticle constructs remained stable under physiological conditions and high/low shear stress, improving over the lower mechanical stability of single-interlinked platforms. Double-interlinked COGELs are processable via suspension 3D printing, unlocking the freeform volumetric writing of nanoparticle inks in protein-based hydrogels volume. The dual-interlinked COGEL technology opens new possibilities for generating user-defined supraparticle architectures with precise volumetric distribution of nanoparticles, both in-air and in-hydrogel platforms. The freedom to select modular multi-particle combinations, as well as the rapid 3D programming of COGEL inks, broadens the range of modular colloidal materials that can be fabricated for a variety of biomedical applications.     

CelloMOF: Nanocellulose Enabled 3D Printing of Metal–Organic Frameworks

3D printing is recognized as a powerful tool to develop complex geometries for a variety of materials including nanocellulose. Herein, a one‐pot synthesis of 3D printable hydrogel ink containing zeolitic imidazolate frameworks (ZIF‐8) anchored on anionic 2,2,6,6‐tetramethylpiperidine‐1‐oxylradical‐mediated oxidized cellulose nanofibers (TOCNF) is presented. The synthesis approach of ZIF‐8@TOCNF (CelloZIF8) hybrid inks is simple, fast (≈30 min), environmentally friendly, takes place at room temperature, and allows easy encapsulation of guest molecules such as curcumin. Shear thinning properties of the hybrid hydrogel inks facilitate the 3D printing of porous scaffolds with excellent shape fidelity. The scaffolds show pH controlled curcumin release. The synthesis route offers a general approach for metal–organic frameworks (MOF) processing and is successfully applied to other types of MOFs such as MIL‐100 (Fe) and other guest molecules as methylene blue. This study may open new venues for MOFs processing and its large‐scale applications.     

Transparent,Anisotropic Biofilm with Aligned Bacterial Cellulose Nanofibers

Cellulose nanofibrils are attractive as building blocks for advanced photonic, optoelectronic, microfluidic, and bio‐based devices ranging from transistors and solar cells to fluidic and biocompatible injectable devices. For the first time, an ultrastrong and ultratough cellulose film, which is composed of densely packed bacterial cellulose (BC) nanofibrils with hierarchical fibril alignments, is successfully demonstrated. The molecular level alignment stems from the intrinsic parallel orientation of crystalline cellulose molecules produced by Acetobacter xylinum. These aligned long‐chain cellulose molecules form subfibrils with a diameter of 2–4 nm, which are further aligned to form nanofibril bundles. The BC film yields a record‐high tensile strength (≈1.0 GPa) and toughness (≈25 MJ m^?3). Being ultrastrong and ultratough, yet the BC film is also highly flexible and can be folded into desirable shapes. The BC film exhibits a controllable manner of alignment and is highly transparent with modulated optical properties, paving the way to enabling new functionalities in mechanical, electrical, fluidic, photonics, and biocompatible applications.     

Complex‐Shaped Cellulose Composites Made by Wet Densification of 3D Printed Scaffolds

Cellulose is an attractive material resource for the fabrication of sustainable functional products, but its processing into structures with complex architecture and high cellulose content remains challenging. Such limitation has prevented cellulose‐based synthetic materials from reaching the level of structural control and mechanical properties observed in their biological counterparts, such as wood and plant tissues. To address this issue, a simple approach is reported to manufacture complex‐shaped cellulose‐based composites, in which the shaping capabilities of 3D printing technologies are combined with a wet densification process that increases the concentration of cellulose in the final printed material. Densification is achieved by exchanging the liquid of the wet printed material with a poor solvent mixture that induces attractive interactions between cellulose particles. The effect of the solvent mixture on the final cellulose concentration is rationalized using solubility parameters that quantify the attractive interparticle interactions. Using X‐ray diffraction analysis and mechanical tests, 3D printed composites obtained through this process are shown to exhibit highly aligned microstructures and mechanical properties significantly higher than those obtained by earlier additively manufactured cellulose‐based materials. These features enable the fabrication of cellulose‐rich synthetic structures that more closely resemble the exquisite designs found in biological materials grown by plants in nature.     

Enabling On-Demand Conformal Zn-Ion Batteries on Non-Developable Surfaces

Conventional power sources encounter difficulties in achieving structural unitization with complex-shaped electronic devices because of their fixed form factors. Here, it is realized that an on-demand conformal Zn-ion battery (ZIB) on non-developable surfaces uses direct ink writing (DIW)-based nonplanar 3D printing. First, ZIB component (manganese oxide-based cathode, Zn powder-based anode, and UV-curable gel composite electrolyte) inks are designed to regulate their colloidal interactions to fulfill the rheological requirements of nonplanar 3D printing, and establish bi-percolating ion/electron conduction pathways, thereby enabling geometrical synchronization with non-developable surfaces, and ensuring reliable electrochemical performance. The ZIB component inks are conformally printed on arbitrary curvilinear substrates to produce embodied ZIBs that can be seamlessly integrated with complicated 3D objects (including human ears). The conformal ZIB exhibits a high fill factor (i.e., areal coverage of cells on underlying substrates, ≈100%) that ensures high volumetric energy density (50.5 mWh cm_cell⁻³), which exceeds those of previously-reported shape-adaptable power sources.     

Patterned Carbon Nitride–Based Hybrid Aerogel Membranes via 3D Printing for Broadband Solar Wastewater Remediation

Controlled scalable assembly of 2D building blocks into macroscopic 3D architectures is highly significant. However, the assembly of g‐C₃N₄ into tailored, 3D architectures is not yet reported. Here, a 3D printing methodology to enable the programmable construction of carbon nitride–based hybrid aerogel membranes with patterned macroscopic architectures is proposed. g‐C₃N₄ nanosheets (CNNS) are used as the building block, and sodium alginate (SA) increases the viscosity of the ink to obtain the desired rheological properties. Three printing routes, including printing directly in air and in the supporting reservoirs composed of CaCl₂/glycerol solution or Pluronic F127, are demonstrated for printing versatility. The printed Au nanobipyramid–CNNS–SA hybrid aerogels exhibit broadband visible‐light absorption and superior solar wastewater remediation performance with excellent cyclic stability and easy manipulation features. Remarkably, the activity of the 3D‐printed aerogel is about 2.5 times of that of the contrast sample, attributing to the enhanced liquid velocity and solution diffusion efficiency because of the 3D‐printed structure, which is demonstrated by experimental and theoretical simulations. This approach can be extended to the macroscopic assembly of other 2D materials for myriad applications.     

3D Printed Multifunctional,Hyperelastic Silicone Rubber Foam

Highly elastic silicone foams, especially those with tunable properties and multifunctionality, are of great interest in numerous fields. However, the liquid nature of silicone precursors and the complicated foaming process hinder the realization of its three‐dimensional (3D) printability. Herein, a series of silicone foams with outstanding performance with regards to elasticity, wetting and sensing properties, multifunctionality, and tunability is generated by direct ink writing. Viscoelastic inks are achieved from direct dispersion of sodium chloride in a unique silicone precursor solution. The 3D‐architectured silicone rubber exhibits open‐celled trimodal porosity, which offers ultraelasticity with hyper compressibility/cycling endurance (near‐zero stress/strain loss under 90% compression or 1000 compression cycles), excellent stretchability (210% strain), and superhydrophobicity. The resulting foam is demonstrated to be multifunctional, such that it can work as an oil sorbent with super capacity (1320%) and customizable soft sensor after absorption of carbon nanotubes on the foam surface. The strategy enables tunability of mechanical strength, elasticity, stretchability, and absorbing capacity, while printing different materials together offers property gradients as an extra dimension of tunability. The first 3D printed silicone foam, which serves an important step toward its application expansion, is achieved.     

Flexible Thermoelectric Devices of Ultrahigh Power Factor by Scalable Printing and Interface Engineering

Printing is a versatile method to transform semiconducting nanoparticle inks into functional and flexible devices. In particular, thermoelectric nanoparticles are attractive building blocks to fabricate flexible devices for energy harvesting and cooling applications. However, the performance of printed devices are plagued by poor interfacial connections between nanoparticles and resulting low carrier mobility. While many rigid bulk materials have shown a thermoelectric figure of merit ZT greater than unity, it is an exacting challenge to develop flexible materials with ZT near unity. Here, a scalable screen‐printing method to fabricate high‐performance and flexible thermoelectric devices is reported. A tellurium‐based nanosolder approach is employed to bridge the interfaces between the BiSbTe particles during the postprinting sintering process. The printed BiSbTe flexible films demonstrate an ultrahigh room‐temperature power factor of 3 mW m^?1 K^?2 and ZT about 1, significantly higher than the best reported values for flexible films. A fully printed thermoelectric generator produces a high power density of 18.8 mW cm^?2 achievable with a small temperature gradient of 80 °C. This screen‐printing method, which directly transforms thermoelectric nanoparticles into high‐performance and flexible devices, presents a significant leap to make thermoelectrics a commercially viable technology for a broad range of energy harvesting and cooling applications.     

Inside Front Cover: Inkjet Printing of Luminescent CdTe Nanocrystal–Polymer Composites (Adv. Funct. Mater. 1/2007)

Schubert and co‐workers have performed a detailed investigation on ink‐jet printing of well‐defined dots of luminescent CdTe nanocrystals (NCs) embedded in a poly(vinyl alcohol) matrix, as reported on p. 23, and subsequently made studies of their morphology and photoluminescence. The inside cover shows a photograph of an ink‐jet‐printed combinatorial library of differently sized CdTe NCs emitting at different wavelengths, and a 3D profilometer image of an array of printed dots. Inkjet printing is used to produce well‐defined patterns of dots (with diameters of ca. 120 μm) that are composed of luminescent CdTe nanocrystals (NCs) embedded within a poly(vinylalcohol) (PVA) matrix. Addition of ethylene glycol (1–2 vol %) to the aqueous solution of CdTe NCs suppresses the well‐known ring‐formation effect in inkjet printing leading to exceptionally uniform dots. Atomic force microscopy characterization reveals that in the CdTe NC films the particle–particle interaction could be prevented using inert PVA as a matrix. Combinatorial libraries of CdTe NC–PVA composites with variable NC sizes and polymer/NC ratios are prepared using inkjet printing. These libraries are subsequently characterized using a UV/fluorescence plate reader to determine their luminescent properties. Energy transfer from green‐light‐emitting to red‐light‐emitting CdTe NCs in the composite containing green‐ (2.6 nm diameter) and red‐emitting (3.5 nm diameter) NCs are demonstrated.     

Ion‐Conductive,Viscosity‐Tunable Hexagonal Boron Nitride Nanosheet Inks

Liquid‐phase exfoliation of layered solids holds promise for the scalable production of 2D nanosheets. When combined with suitable solvents and stabilizing polymers, the rheology of the resulting nanosheet dispersions can be tuned for a variety of additive manufacturing methods. While significant progress is made in the development of electrically conductive nanosheet inks, minimal effort is applied to ion‐conductive nanosheet inks despite their central role in energy storage applications. Here, the formulation of viscosity‐tunable hexagonal boron nitride (hBN) inks compatible with a wide range of printing methods that span the spectrum from low‐viscosity inkjet printing to high‐viscosity blade coating is demonstrated. The inks are prepared by liquid‐phase exfoliation with ethyl cellulose as the polymer dispersant and stabilizer. Thermal annealing of the printed structures volatilizes the polymer, resulting in a porous microstructure and the formation of a nanoscale carbonaceous coating on the hBN nanosheets, which promotes high wettability to battery electrolytes. The final result is a printed hBN nanosheet film that possesses high ionic conductivity, chemical and thermal stability, and electrically insulating character, which are ideal characteristics for printable battery components such as separators. Indeed, lithium‐ion battery cells based on printed hBN separators reveal enhanced electrochemical performance that exceeds commercial polymer separators.     

Additive Manufacturing of Batteries

Additive manufacturing, i.e., 3D printing, is being increasingly utilized to fabricate a variety of complex‐shaped electronics and energy devices (e.g., batteries, supercapacitors, and solar cells) due to its excellent process flexibility, good geometry controllability, as well as cost and material waste reduction. In this review, the recent advances in 3D printing of emerging batteries are emphasized and discussed. The recent progress in fabricating 3D‐printed batteries through the major 3D‐printing methods, including lithography‐based 3D printing, template‐assisted electrodeposition‐based 3D printing, inkjet printing, direct ink writing, fused deposition modeling, and aerosol jet printing, are first summarized. Then, the significant achievements made in the development and printing of battery electrodes and electrolytes are highlighted. Finally, major challenges are discussed and potential research frontiers in developing 3D‐printed batteries are proposed. It is expected that with the continuous development of printing techniques and materials, 3D‐printed batteries with long‐term durability, favorable safety as well as high energy and power density will eventually be widely used in many fields.     

A Subtractive Photoresist Platform for Micro‐ and Macroscopic 3D Printed Structures

The selective removal of structural elements plays a decisive role in 3D printing applications enabling complex geometries. To date, the fabrication of complex structures on the microscale is severely limited by multistep processes. Herein, a subtractive photoresist platform technology that is transferable from microscopic 3D printing via direct laser writing to macroscopic structures via stereolithography is reported. All resist components are readily accessible and exchangeable, offering fast adaptation of the resist's property profile. The micro‐ and macroprinted structures can be removed in a facile fashion, without affecting objects based on standard photoresists. The cleavage is analyzed by time‐lapse optical microscopy as well as via in‐depth spectroscopic assessment. The mechanical properties of the printed materials are investigated by nanoindentation. Critically, the power of the subtractive resist platform is demonstrated by constructing complex 3D objects with flying features on the microscale.