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Abstract During drying, liquid‐applied particulate coatings develop stress and are consequently prone to stress‐induced defects, such as cracking, curling, and delamination. In this work, the stress development and cracking of coatings, prepared from aqueous silica and zinc oxide particle suspensions, were characterized using cantilever beam deflection with simultaneous imaging of the coating surface. Drying uniformity was improved and lateral or edge‐in drying was discouraged by using thin silicone walls around the perimeter of the cantilever. Coatings prepared from larger monodisperse silica particles (D₅₀∼ 0.9 µm) dried uniformly but had a high critical cracking thickness (>150 µm) that prevented simultaneous study of stress development and cracking. Coatings prepared from smaller silica particles (D₅₀∼ 0.3 µm) cracked readily at low thicknesses but exhibited edge‐in drying that complicated the stress measurement data. This drying nonuniformity was connected to the potential for these small particles to accumulate at the coating surface during drying. Hence, the selection of particle size and density was critical to drying uniformity when characterizing stress development and cracking. Coatings prepared from suspensions of zinc oxide particles (D₅₀∼ 0.4 µm) were well‐suited for these studies, with uniform drying stress peaking at ∼1 MPa. Characteristic features in the stress development data above and below the critical cracking thickness (53 µm) were identified, demonstrating that cantilever beam deflection is a useful tool for studying the effectiveness of crack mitigation methods and the fundamentals of coating fracture during drying. 

Capillary flow of liquids plays a key role in many applications including lab-on-a-chip devices, heat pipes and printed electronics manufacturing. Open rectangular microchannels often appear in these applications, with the lack of a top resulting in a complex free-surface morphology and evaporation. In this work we develop a theoretical model based on lubrication theory and kinetically limited evaporation to examine capillary flow of evaporating liquid solutions in open rectangular microchannels connected to circular reservoirs. The model accounts for the complex free-surface morphology, solvent evaporation, Marangoni flows due to gradients in solute concentration and temperature and finite-size reservoir effects. Significant differences are predicted in flow behaviour between pure liquids and liquid solutions due to solvent evaporation and solute transport. Marangoni flows are found to promote more uniform solute deposition patterns after solvent evaporation. Model predictions of meniscus position evolution are in good agreement with prior capillary-flow experiments of aqueous poly(vinyl alcohol) solutions in the presence of evaporation. The model reveals that the principal mechanism through which evaporation influences the meniscus position in the experiments is the increase in viscosity with solute concentration. 

Many natural organisms, such as fungal hyphae and plant roots, grow at their tips, enabling the generation of complex bodies composed of natural materials as well as dexterous movement and exploration. Tip growth presents an exemplary process by which materials synthesis and actuation are coupled, providing a blueprint for how growth could be realized in a synthetic system. Herein, we identify three underlying principles essential to tip-based growth of biological organisms: a fluid pressure driving force, localized polymerization for generating structure, and fluid-mediated transport of constituent materials. In this work, these evolved features inspire a synthetic materials growth process called extrusion by self-lubricated interface photopolymerization (E-SLIP), which can continuously fabricate solid profiled polymer parts with tunable mechanical properties from liquid precursors. To demonstrate the utility of E-SLIP, we create a tip-growing soft robot, outline its fundamental governing principles, and highlight its capabilities for growth at speeds up to 12 cm/min and lengths up to 1.5 m. This growing soft robot is capable of executing a range of tasks, including exploration, burrowing, and traversing tortuous paths, which highlight the potential for synthetic growth as a platform for on-demand manufacturing of infrastructure, exploration, and sensing in a variety of environments. 

Transparent conductive oxides (TCOs) are widely used in optoelectronic devices such as flat-panel displays and solar cells. A significant optical property of TCOs is their band gap, which determines the spectral range of the transparency of the material. In this study, a tunable band gap range from 3.35 eV to 3.53 eV is achieved for zinc oxide (ZnO) nanocrystals (NCs) films synthesized by nonthermal plasmas through the removal of surface groups using atomic layer deposition (ALD) coating of Al2O3 and intense pulsed light (IPL) photo-doping. The Al2O3 coating is found to be necessary for band gap tuning, as it protects ZnO NCs from interactions with the ambient and prevents the formation of electron traps. With respect to the solar spectrum, the 0.18 eV band gap shift would allow ~4.1% more photons to pass through the transparent layer, for instance, into a CH3NH3PbX3 solar cell beneath. The mechanism of band gap tuning via photo-doping appears to be related to a combination of the Burstein–Moss (BM) and band gap renormalization (BGN) effects due to the significant number of electrons released from trap states after the removal of hydroxyl groups. The BM effect shifts the conduction band edge and enlarges the band gap, while the BGN effect narrows the band gap.