Session: 20-17-01: Rising Stars of Mechanical Engineering

Paper Number: 172829

Scalable Multimaterial Printing of Bioinspired Heterogeneous Materials 

The integration of metal and polymer materials into complex, multimaterial architectures is essential for a wide range of emerging technologies, including 3D electronics, conformal antennas, flexible sensors, soft actuators, quantum devices, and metamaterials. Despite their potential, existing fabrication methods face significant limitations. Conventional microfabrication techniques such as lithography, physical vapor deposition, and etching are inherently planar, costly, and incompatible with the freeform geometries and internal features characteristic of 3D-printed polymer objects. While additive manufacturing (AM) offers geometric flexibility, current hybrid metal-polymer AM methods are often hindered by high operational complexity, limited pattern resolution, long processing times, expensive equipment, and restrictions in the co-processing of dissimilar materials. This NSF CAREER award supports research on a fundamentally new multimaterial AM strategy that combines spatially programmable, electric field-assisted metal electrodeposition with photopolymerization-based 3D printing. The proposed process enables direct, in situ metallization within or onto photopolymer structures, without the need for post-processing steps, vacuum systems, or cleanroom facilities. By integrating the metal deposition mechanism into the photopolymer build cycle through controlled electrical stimuli, this method unlocks unprecedented capabilities for embedding conductive patterns, functional surfaces, and reinforcement structures directly during polymer part fabrication, with high spatial resolution and design customizability.

The overarching goal is to establish a unified, scalable manufacturing platform capable of producing intricate meta-polymer architectures with embedded metal features in a single, seamless process. This will be achieved through a systematic research plan combining process development, multiphysics simulation, and experimental validation. Specific research objectives include: (1) uncovering how electric field distribution, patterning strategies, and electrochemical parameters control the nucleation, growth, and morphology of metal structures on and within polymer matrices; (2) correlating surface topology, interfacial microstructure, and deposition dynamics with mechanical properties, thermal performance, and printing efficiency; and (3) understanding the roles of thermal transport, ion diffusion, and solution chemistry in the fidelity and stability of the printed metal/polymer interfaces. By advancing the fundamental understanding of field-directed electrochemical growth in polymer systems, this work aims to develop design rules and process models that govern the spatial distribution and integration of metal features within AM-produced polymer architectures. The anticipated outcomes will provide a robust scientific foundation for next-generation hybrid manufacturing platforms and enable new applications in energy harvesting, aerospace structures, biomedical devices, thermal regulation, and beyond. In addition to its research contributions, the project integrates education and outreach components that promote interdisciplinary learning, foster innovation, and broaden participation in manufacturing science across underrepresented communities and early-career learners.

Presenting Author: Xiangjia Li Arizona State University

Presenting Author Biography: Dr. Cindy (Xiangjia) Li, an Assistant Professor at Arizona State University, specializes in additive manufacturing, developing multiscale and multi-material processes to create bioinspired hierarchical structures with programmable material distribution. Her work addresses challenges in interfacial engineering, biomedical applications, optics, and flexible devices. Dr. Li has earned numerous accolades, including Best Paper at ASME MSEC 2022 and 2023, Best Poster at MSEC 2024, the SME Outstanding Young Manufacturing Engineer Award, and the NSF CAREER Award. She holds several U.S. patents and has received the USC Stevens Center Innovation Commercialization Award for her contributions to the field.

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