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

Paper Number: 172838

Selective Cooling Crystallization for 3d Printing of Bioinspired Heterostructured Hybrid Materials 

Nature has evolved sophisticated composite materials, such as bone and nacre, that combine lightweight properties with exceptional strength, toughness, and impact resistance through intricate biomineralization processes. Inspired by these natural designs, bioinspired hybrid materials have emerged as promising candidates for applications in sports equipment, biomedical engineering, and consumer electronics. However, traditional bottom-up assembly and additive manufacturing (AM) techniques face significant challenges in achieving high ceramic loading, precise crystal size control, and controlled distribution within polymer frameworks, limiting their functionality. This research addresses these limitations by developing a novel AM technique that integrates photo-induced polymerization with layered cooling crystallization to mimic natural biomineralization processes. The successful implementation of this method will enable the precise fabrication of rigid materials in specific regions of polymer frameworks, significantly enhancing material performance. Additionally, this project includes educational initiatives to engage students across the U.S., fostering a highly skilled workforce and strengthening America’s talent pipeline in advanced manufacturing.

The primary contribution of this work is the development of a scalable and efficient multi-material AM technique that produces dual-material properties using a single resin, eliminating the need for post-processing while improving manufacturing precision. The proposed layered cooling crystallization AM approach allows for programmable crystal growth within photopolymerized polymer matrices, offering unprecedented control over material properties. This research advances scientific understanding of the complex interplay between cooling parameters (temperature, cooling time, and rate), resin chemistry (composition and supersaturation level), and bioinspired polymer patterns (structures, wettability, and roughness) on nucleation, crystal growth dynamics, and interfacial bonding. By employing advanced computational simulations and experimental techniques, this study elucidates the relationships between thermal fields, crystallization kinetics, material properties, and the resulting functionalities of hybrid materials.

Preliminary results demonstrate the feasibility of controlling crystal distribution and morphology through tailored cooling strategies and resin formulations. Experimental validation confirms that optimized cooling rates and polymer surface modifications enhance crystal adhesion and mechanical performance. Computational models further predict crystallization behavior under varying thermal conditions, providing a foundation for process optimization. The findings from this research will establish a robust framework for designing multifunctional materials with applications in smart protective gear, biomedical implants, and high-performance structural components.

In conclusion, this project bridges the gap between bioinspired material design and advanced manufacturing by introducing a transformative AM technique that mimics natural growth processes. The outcomes will not only expand fundamental knowledge in crystallization dynamics and hybrid material fabrication but also drive innovation in industrial applications. By integrating research with education, this work will cultivate a new generation of engineers and scientists equipped to tackle critical challenges in materials science and manufacturing, ultimately contributing to economic growth and technological leadership

Presenting Author: YANG YANG San Diego State University

Presenting Author Biography: Dr. Yang Yang’s research focuses on the machine, materials, and structures development for bioinspired 3D printing. He received his B.S. in Physics from Wuhan University in 2009. He completed the joint Ph.D. at Wuhan University and University of California, Los Angeles (UCLA) in Physics and Bioengineering in 2015. Prior to joining SDSU, Dr. Yang is a Postdoc at The University of Southern California (USC) in the Department of Industrial and Systems Engineering and Center for Advanced Manufacturing. He has received the '2022 SME Sandra L. Bouckley Outstanding Young Manufacturing Engineer Award' and has authored over 50 peer-reviewed publications such as ''Nature Communications', Science Advances', 'Advanced Materials', 'Energy & Environmental Science', 'Research' and he is the reviewer of several journals such as ‘Advanced Materials’, ‘Small’, and ‘Additive Manufacturing’. His work has been supported by NSF and SDSU seed grants.

Authors: