An official website of the United States government
Abstract Aerosol jet printing offers high resolution, broad materials compatibility, and digital patterning for flexible, conformal, and hybrid electronics. However, limited throughput, instability, and complex optimization requirements inhibit translation to industrial applications. An in‐line heater integrated on a custom printer is demonstrated to modulate droplet evaporation in the aerosol phase, thereby decoupling the deposition rate of functional solids and liquid ink to enable taller, narrower features with aspect ratios reaching 0.29 for a single line. Heating the printhead from room temperature to 80 °C reduced the sensitivity of resolution to deposition rate by ≈90%, improving reliability. With this strategy, increasing the linear deposition rate by 10x results in a modest increase of 27% in line width, compared to a four‐fold increase without heating, permitting higher throughput without sacrificing print quality. Providing a control for in‐line drying independent of ink formulation enables rapid, straightforward design of new materials and processes. This ability to engineer drying of droplets prior to impingement provides a versatile tool to meet complex fabrication challenges, as demonstrated here for both high aspect ratio printing and conformal patterning on rough and three‐dimensional surfaces.
more »
« less
Room temperature 3D carbon microprinting
Abstract Manufacturing custom three-dimensional (3D) carbon functional materials is of utmost importance for applications ranging from electronics and energy devices to medicine, and beyond. In lieu of viable eco-friendly synthesis pathways, conventional methods of carbon growth involve energy-intensive processes with inherent limitations of substrate compatibility. The yearning to produce complex structures, with ultra-high aspect ratios, further impedes the quest for eco-friendly and scalable paths toward 3D carbon-based materials patterning. Here, we demonstrate a facile process for carbon 3D printing at room temperature, using low-power visible light and a metal-free catalyst. Within seconds to minutes, this one-step photocatalytic growth yields rod-shaped microstructures with aspect ratios up to ~500 and diameters below 10 μm. The approach enables the rapid patterning of centimeter-size arrays of rods with tunable height and pitch, and of custom complex 3D structures. The patterned structures exhibit appealing luminescence properties and ohmic behavior, with great potential for optoelectronics and sensing applications, including those interfacing with biological systems.
more »
« less
- Award ID(s):
- 1847830
- PAR ID:
- 10497680
- Publisher / Repository:
- Nature Publishing Group
- Date Published:
- Journal Name:
- Nature Communications
- Volume:
- 15
- Issue:
- 1
- ISSN:
- 2041-1723
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract Extrusion 3D‐printing of biopolymers and natural fiber‐based biocomposites enables the fabrication of complex structures, ranging from implants' scaffolds to eco‐friendly structural materials. However, conventional polymer extrusion requires high energy consumption to reduce viscosity, and natural fiber reinforcement often requires harsh chemical treatments to improve adhesion. We address these challenges by introducing a sustainable framework to fabricate natural biocomposites usingChlorella vulgarismicroalgae as the matrix. Through bioink optimization and process refinement, we produced lightweight, multifunctional materials with hierarchical architectures. Infrared spectroscopy analysis reveals that hydrogen bonding plays a critical role in the binding and reinforcement ofChlorellacells by hydroxyethyl cellulose (HEC). As water content decreases, the hydrogen bonding network evolves from water‐mediated interactions to direct hydrogen bonds between HEC andChlorella, enhancing the mechanical properties. A controlled dehydration process maintains continuous microalgae morphology, preventing cracking. The resulting biocomposites exhibit a bending stiffness of 1.6 GPa and isotropic heat transfer and thermal conductivity of 0.10 W/mK at room temperature, demonstrating effective thermal insulation. These characteristics makeChlorellabiocomposites promising candidates for applications requiring both structural performance and thermal insulation, offering a sustainable alternative to conventional materials in response to growing environmental demands.more » « less
-
Summary Global food production faces persistent threats from environmental challenges and pathogenic attacks, leading to significant yield losses. Conventional strategies to combat pathogens, such as fungicides and disease‐resistant breeding, are limited by environmental contamination and emergence of pathogen resistance. Herein, we engineered sunlight‐sensitive and biodegradable carbon dots (CDs) capable of generating reactive oxygen species (ROS), offering a novel and sustainable approach for plant protection. Our study demonstrates that CDs function as dual‐purpose materials: priming plant immune responses and serving as broad‐spectrum antifungal agents. Foliar application of CDs generated ROS under light, and the ROS could damage the plant cell wall and trigger cell wall‐mediated immunity. Immune activation enhanced plant resistance against pathogens without compromising photosynthetic efficiency or yield. Specifically, spray treatment with CDs at 240 mg/L (2 mL per plant) reduced the incidence of grey mould inN. benthamianaand tomato leaves by 44% and 12%, respectively, and late blight in tomato leaves by 31%. Moreover, CDs (480 mg/L, 1 mL) combined with continuous sunlight irradiation (simulated by xenon lamp, 9.4 × 105lux) showed a broad‐spectrum antifungal activity. The inhibition ratios for mycelium growth were 66.5% forP. capsici, 8% forS. sclerotiorumand 100% forB. cinerea, respectively. Mechanistic studies revealed that CDs effectively inhibited mycelium growth by damaging hyphae and spore structures, thereby disrupting the propagation and vitality of pathogens. These findings suggest that CDs offer a promising, eco‐friendly strategy for sustainable crop protection, with potential for practical agricultural applications that maintain crop yields and minimize environmental impact.more » « less
-
The rapid proliferation of the Internet of Things (IoT) necessitates compact, sustainable, and autonomous energy sources for distributed electronic devices. Microbial fuel cells (MFCs) offer an eco‐friendly alternative by converting organic matter into electrical energy using living micro‐organisms. However, their integration into microsystems faces significant challenges, including incompatibility with microfabrication, fragile anode materials, low electrical conductivity, and compromised microbial viability. Here, this study introduces a microscale biobattery platform integrating laser powder bed fusion‐fabricated 316L stainless steel anodes with resilient, spore‐formingBacillus subtilisbiocatalysts. The 3D‐printed gyroid scaffolds provide high surface‐to‐volume ratios, submillimeter porosity, and tunable roughness, enhancing microbial colonization and electron transfer. The stainless steel ensures mechanical robustness, chemical stability, and superior conductivity.Bacillus subtilisspores withstand harsh conditions, enabling prolonged storage and rapid, on‐demand activation. The biobattery produces 130 μW of power, exceeding conventional microscale MFCs, with exceptional reuse stability. A stack of six biobatteries achieves nearly 1 mW, successfully powering a 3.2‐inch thin‐film transistor liquid crystal display via capacitor‐assisted energy buffering, demonstrating practical applicability. This scalable, biologically resilient, and fabrication‐compatible solution advances autonomous electronic systems for IoT applications.more » « less
-
Buildings consume over half of annual energy supply as embodied and operating energy in their construction and operation releasing harmful emissions to the atmosphere. Over 90 % of the embodied energy is attributed to construction materials used in building structure, envelope, and interiors that must be reduced to minimize material use. Concrete is one of the major materials that contributes significantly to the energy and carbon footprint of buildings, as it is responsible for 5-9 % of global carbon emission. Because most of the concrete use in the building sector occurs in building structures, assessing how building design parameters influence its environmental sustainability is important. One of the design parameters that impact the sustainability of buildings is the aspect ratio, which is defined as the ratio of horizontal to vertical surface area of a building. A building with the same floor area can be designed horizontally or vertically with different aspect ratios, which will influence its structural design and eventually the amount of concrete used in the building. In this paper, we examine how aspect ratio may affect the environmental sustainability of a buildings foundation, structural framing, and slab. We model the structure of a generic building with different aspect ratio to analyze if aspect ratio can help reduce the energy and carbon embodied in reinforced concrete structures.more » « less
