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We developed a physics-informed machine learning platform that predicts stress–strain curves of 3D-printed thermoplastics from ink formulations, enabling virtual experimentation and rapid identification of optimal materials in vast chemical spaces. 

In nature, structural and functional materials often form programmed three-dimensional (3D) assembly to perform daily functions, inspiring researchers to engineer multifunctional 3D structures. Despite much progress, a general method to fabricate and assemble a broad range of materials into functional 3D objects remains limited. Herein, to bridge the gap, we demonstrate a freeform multimaterial assembly process (FMAP) by integrating 3D printing (fused filament fabrication (FFF), direct ink writing (DIW)) with freeform laser induction (FLI). 3D printing performs the 3D structural material assembly, while FLI fabricates the functional materials in predesigned 3D space by synergistic, programmed control. This paper showcases the versatility of FMAP in spatially fabricating various types of functional materials (metals, semiconductors) within 3D structures for applications in crossbar circuits for LED display, a strain sensor for multifunctional springs and haptic manipulators, a UV sensor, a 3D electromagnet as a magnetic encoder, capacitive sensors for human machine interface, and an integrated microfluidic reactor with a built-in Joule heater for nanomaterial synthesis. This success underscores the potential of FMAP to redefine 3D printing and FLI for programmed multimaterial assembly. 

Rapid analysis of materials characterization spectra is pivotal for preventing the accumulation of unwieldy datasets, thus accelerating subsequent decision-making. However, current methods heavily rely on experience and domain knowledge, which not only proves tedious but also makes it hard to keep up with the pace of data acquisition. In this context, we introduce a transferable Vision Transformer (ViT) model for the identification of materials from their spectra, including XRD and FTIR. First, an optimal ViT model was trained to predict metal organic frameworks (MOFs) from their XRD spectra. It attains prediction accuracies of 70%, 93%, and 94.9% for Top-1, Top-3, and Top-5, respectively, and a shorter training time of 269 seconds (∼30% faster) in comparison to a convolutional neural network model. The dimension reduction and attention weight map underline its adeptness at capturing relevant features in the XRD spectra for determining the prediction outcome. Moreover, the model can be transferred to a new one for prediction of organic molecules from their FTIR spectra, attaining remarkable Top-1, Top-3, and Top-5 prediction accuracies of 84%, 94.1%, and 96.7%, respectively. The introduced ViT-based model would set a new avenue for handling diverse types of spectroscopic data, thus expediting the materials characterization processes. 

The printing outcome of vat photopolymerization (VPP) of thermoplastics largely depends on physicochemical properties of monomers and their compositions in resins, which also greatly determine the material properties, e.g., tensile strength (σT) and toughness (UT)and phase transition temperature (Tg). A methodology for optimizing the resin formulation is of paramount importance in realizing highly printable thermoplastics with balanced σT/UT and target Tg while remaining largely underexplored. Herein, we introduce a multi-objective Bayesian optimization (MOBO) algorithm under two physics informed constraints (printability and Tg) to optimize two conflicting properties: σT and UT. The two constraints are formulated as two machine learning (ML) models, which are trained with weight ratios of the six monomers and physics informed (PI) descriptors derived from their physiochemical parameters. Dimensional reduction analysis reveals that the algorithm avoids recommendation of the monomer ratios that do not pass the two constraints. The printing failure rate is reduced from 16% in the background experiments to 3% in the recommended experiments. Within only 36 iterations (72 samples), the MOBO algorithm successfully identifies five sets of ratios leading to Pareto optimal of σT and UT. Due to the constraint in Tg they show appropriate Tg for shape memory application. The partial dependence analysis indicates that σT and UT depend on both the ratios and physiochemical features of the monomers. These results underscore capability of such a smart decision-making algorithm—with constraints that are not fully understood but can be informed by prior knowledge—in planning the experiments from the vast design space, thus holding a great promise for broader applications in materials design and manufacturing.