Session: 03-01-02: Annual Conference-Wide Symposium on Additive Manufacturing

Paper Number: 150335

150335 - High-Throughput and Hybrid Additive Manufacturing of Multifunctional Materials and Devices 

We report versatile high-throughput and hybrid additive manufacturing methods to manufacture and transform a broad range of emerging nanoscale building blocks into advanced energy, sensing and electronic systems in a highly scalable and autonomous manner.

I will first present a high-throughput combinatorial printing (HTCP) method capable of fabricating materials with compositional gradients with microscale spatial resolution. ¹ The in situ “mix and print” in the aerosol phase allows instantaneous tuning of the mixing ratio of a broad range of materials on the fly, which is an important feature unobtainable in conventional multi-materials printing using feedstocks in liquid/liquid or solid/solid phases. We demonstrate a variety of high-throughput printing strategies and applications in combinatorial materials discovery, functional grading, and chemical reaction, enabling materials explorations of doped chalcogenides and compositionally graded materials with gradient properties. The aerosol based HTCP enables universal printing and integration of a broad range of materials including metals, semiconductors, dielectrics, as well as polymers and biomaterials, leading to facile fabrication of multifunctional and flexible/wearable devices for energy conversion/storage, sensing, and health monitoring.

The advent of 3D printing has facilitated the rapid fabrication of microfluidic devices that are accessible and cost-effective. However, it remains a challenge to fabricate sophisticated microfluidic devices with integrated structural and functional components due to limited material options of existing printing methods and their stringent requirement on feedstock material properties. Here, we report a multi-materials multi-scale hybrid printing method that enables seamless integration of a broad range of structural and functional materials into complex devices.^2,3 A fully printed and assembly-free microfluidic biosensor with embedded fluidic channels and functionalized electrodes at sub-100 μm spatial resolution for the amperometric sensing of lactate in sweat is demonstrated. The sensors present a sensitive response with a limit of detection of 442 nm and a linear dynamic range of 1–10 mm, which are performance characteristics relevant to physiological levels of lactate in sweat. The versatile hybrid printing method offers a new pathway toward facile fabrication of next-generation integrated devices for broad applications in point-of-care health monitoring and sensing.

The ability to combine the top-down design freedom of additive manufacturing with bottom-up control over the local material compositions promises compositionally complex materials inaccessible via conventional manufacturing approaches. The fabrication freedom and data-rich nature of hybrid and high-throughput additive manufacturing along with machine learning and artificial intelligence guided design strategies is expected to accelerate the development of a broad range of materials and devices with intriguing and unprecedented properties for emerging applications.

 

References:

1 Zeng, M., Du, Y., Jiang, Q., Kempf, N., Wei, C., Bimrose, M. V., Tanvir, A. N. M., Xu, H., Chen, J., Kirsch, D. J., Martin, J., Wyatt, B. C., Hayashi, T., Saeidi-Javash, M., Sakaue, H., Anasori, B., Jin, L., Mcmurtrey, M. D. & Zhang, Y. High-throughput printing of combinatorial materials from aerosols. Nature, 617, 292-298 (2023).

2 Du, Y., Reitemeier, J., Jiang, Q., Bappy, M. O., Bohn, P. W. & Zhang, Y. Hybrid Printing of Fully Integrated Microfluidic Devices for Biosensing. Small, 2304966 (2023).

3 Du, Y.; Wang, R.; Zeng, M.; Xu, S.; Saeidi-Javash, M.; Wu, W.; Zhang, Y. Hybrid Printing of Wearable Piezoelectric Sensors. Nano Energy, 90, 106522 (2021).

 

Presenting Author: Yanliang Zhang University of Notre Dame

Presenting Author Biography: Yanliang Zhang is the Advanced Materials and Manufacturing Collegiate Chair and Associate Professor at University of Notre Dame. He received his Ph.D. in Mechanical Engineering from Rensselaer Polytechnic Institute in 2011, and his M.S. and B.S. from Southeast University in 2008 and 2005. His research focuses on additive manufacturing, scalable nanomanufacturing, autonomous and hybrid manufacturing, advanced materials and devices for energy conversion, sensing, and health monitoring. He has received honors including NSF Career Award, Young Investigator Award from International Thermoelectric Society, IBM Fellowship award, and multiple best paper awards at international conferences. He has published papers on top journals including Nature, Nature Materials, Energy and Environmental Science, Chemical Society Review, Advanced Materials, etc.

Authors:

Yanliang Zhang University of Notre Dame