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Ultrasound directed self-assembly (DSA) allows organizing particles dispersed in a fluid medium into user-specified patterns, driven by the acoustic radiation force associated with a standing ultrasound wave. Accurate control of the spatial organization of the particles in the fluid medium requires accounting for medium viscosity and particle volume fraction. However, existing theories consider an inviscid medium or only determine the effect of viscosity on the magnitude of the acoustic radiation force rather than the locations where particles assemble, which is crucial information to use ultrasound DSA as a fabrication method. We experimentally measure the deviation between locations where spherical microparticles assemble during ultrasound DSA as a function of medium viscosity and particle volume fraction. Additionally, we simulate the experiments using coupled-phase theory and the time-averaged acoustic radiation potential, and we derive best-fit equations that predict the deviation between locations where particles assemble during ultrasound DSA when using viscous and inviscid theory. We show that the deviation between locations where particles assemble in viscous and inviscid media first increases and then decreases with increasing particle volume fraction and medium viscosity, which we explain by means of the sound propagation velocity of the mixture. This work has implications for using ultrasound DSA to fabricate, e.g., engineered polymer composite materials that derive their function from accurately organizing a pattern of particles embedded in the polymer matrix. 

Fabricating polymer-matrix composite materials with microfibers aligned along a user-specified direction is important to obtain specific material properties, such as anisotropic electrical and thermal conductivity and improved mechanical strength. We quantify macro- and microscale alignment of microfibers embedded in photopolymer resin, 3D-printed using ultrasound directed self-assembly (DSA) and stereolithography, as a function of three dimensionless input parameters: microfiber weight fraction, dimensionless ultrasound transducer input power, and dimensionless ultrasound transducer separation distance. We use regression analysis to determine microfiber alignment as a function of the fabrication process parameters. Microscale alignment is primarily determined by microfiber weight fraction, whereas macroscale alignment is a function of microfiber weight fraction, dimensionless ultrasound transducer separation distance, and dimensionless ultrasound transducer input power. Relating microfiber alignment to the fabrication process parameters is a crucial step towards 3D-printing composite materials with specific anisotropic material properties. 

Bioinspired fabrication techniques that are able to mimic the structure and properties of biological materials are of interest to a wide range of scientific and engineering fields. We propose that these bioinspired techniques can be controlled through either intrinsic (those that modify from within by altering the constituents) or extrinsic (those that apply external forces or templates) means. Through these classifications, examples of extrinsic (through energized magnetic and ultrasound external fields) freeze cast, aerogel, and FDM printed structures will be discussed with a focus on providing advanced control of the final material structure and properties. Applications in biomedical and filtration technologies will be discussed. 

Bioinspired fabrication techniques that are able to mimic the structure and properties of biological materials are of interest to a wide range of scientific and engineering fields. We propose that these bioinspired techniques can be controlled through either intrinsic (those that modify from within by altering the constituents) or extrinsic (those that apply external forces or templates) means. Through these classifications, examples of extrinsic (through energized magnetic and ultrasound external fields) freeze cast, aerogel, and FDM printed structures will be discussed with a focus on providing advanced control of the final material structure and properties. Applications in biomedical and defense applications will be discussed. 

The ability to fabricate polymer matrix composite materials with continuous or discontinuous filler material, oriented in a user‐specified direction, enables implementing designer material properties, such as anisotropic mechanical, thermal, and electrical properties. Conventional fabrication methods rely on a mold, which limits specimen geometry and is difficult to implement. In contrast, additive manufacturing, including fused filament fabrication or fused deposition modeling, direct ink writing, or stereolithography, combined with a method to align filler material such as a mechanical force or an electric, magnetic, shear force, or ultrasound wave field, enables 3D printing polymer matrix composite material specimens with complex geometry and aligned filler material, without the need for a mold. Herein, we review the combinations of fabrication and filler material alignment methods used to fabricate polymer matrix composite materials, in terms of operating and design parameters including size, resolution, print speed, filler material alignment time, polymer matrix and filler material requirements, and filler manipulation requirements. The operating envelope of each fabrication method is described and their advantages, disadvantages, and limitations are discussed. Finally, different combinations of 3D printing and filler material alignment methods in the context of important engineering applications, such as structural materials, flexible electronics, and shape‐changing materials, are illustrated.