Noninvasive Detection, Tracking, and Characterization of Aerogel Implants Using Diagnostic Ultrasound.

Medical implants are routinely tracked and monitored using different techniques, such as MRI, X-ray, and ultrasound. Due to the need for ionizing radiation, the two former methods pose a significant risk to tissue. Ultrasound imaging, however, is non-invasive and presents no known risk to human tissue. Aerogels are an emerging material with great potential in biomedical implants. While qualitative observation of ultrasound images by experts can already provide a lot of information about the implants and the surrounding structures, this paper describes the development and study of two simple B-Mode image analysis techniques based on attenuation measurements and echogenicity comparisons, which can further enhance the study of the biological tissues and implants, especially of different types of biocompatible aerogels.

Three-Dimensional Printed MoS2/Graphene Aerogel Electrodes for Hydrogen Evolution Reactions.

In this work, we demonstrate the use of direct ink writing (DIW) technology to create 3D catalytic electrodes for electrochemical applications. Hybrid MoS2/graphene aerogels are made by mixing commercially available MoS2 and graphene oxide powders into a thixotropic, high concentration, viscous ink. A porous 3D structure of 2D graphene sheets and MoS2 particles was created after post treatment by freeze-drying and reducing graphene oxide through annealing. The composition and morphology of the samples were fully characterized through XPS, BET, and SEM/EDS. The resulting 3D printed MoS2/graphene aerogel electrodes had a remarkable electrochemically active surface area (>1700 cm2) and were able to achieve currents over 100 mA in acidic media. Notably, the catalytic activity of the MoS2/graphene aerogel electrodes was maintained with minimal loss in surface area compared to the non-3D printed electrodes, suggesting that DIW can be a viable method of producing durable electrodes with a high surface area for water splitting. This demonstrates that 3D printing a MoS2/graphene 3D porous network directly using our approach not only improves electrolyte dispersion and facilitates catalyst utilization but also provides multidimensional electron transport channels for improving electronic conductivity.

Efficient Hydrogen Delivery for Microbial Electrosynthesis via 3D-Printed Cathodes.

The efficient delivery of electrochemically in situ produced H2 can be a key advantage of microbial electrosynthesis over traditional gas fermentation. However, the technical details of how to supply large amounts of electric current per volume in a biocompatible manner remain unresolved. Here, we explored for the first time the flexibility of complex 3D-printed custom electrodes to fine tune H2 delivery during microbial electrosynthesis. Using a model system for H2-mediated electromethanogenesis comprised of 3D fabricated carbon aerogel cathodes plated with nickel-molybdenum and Methanococcus maripaludis, we showed that novel 3D-printed cathodes facilitated sustained and efficient electromethanogenesis from electricity and CO2 at an unprecedented volumetric production rate of 2.2 L CH4 /L catholyte /day and at a coulombic efficiency of 99%. Importantly, our experiments revealed that the efficiency of this process strongly depends on the current density. At identical total current supplied, larger surface area cathodes enabled higher methane production and minimized escape of H2. Specifically, low current density (<1 mA/cm2) enabled by high surface area cathodes was found to be critical for fast start-up times of the microbial culture, stable steady state performance, and high coulombic efficiencies. Our data demonstrate that 3D-printing of electrodes presents a promising design tool to mitigate effects of bubble formation and local pH gradients within the boundary layer and, thus, resolve key critical limitations for in situ electron delivery in microbial electrosynthesis.

Inertially enhanced mass transport using 3D-printed porous flow-through electrodes with periodic lattice structures.

Electrochemical reactors utilizing flow-through electrodes (FTEs) provide an attractive path toward the efficient utilization of electrical energy, but their commercial viability and ultimate adoption hinge on attaining high currents to drive productivity and cost competitiveness. Conventional FTEs composed of random, porous media provide limited opportunity for architectural control and engineering of microscale transport. Alternatively, the design freedom engendered by additively manufacturing FTEs yields additional opportunities to further drive performance via flow engineering. Through experiment and validated continuum computation we analyze the mass transfer in three-dimensional (3D)-printed porous FTEs with periodic lattice structures and show that, in contrast to conventional electrodes, the mesoscopic length scales in 3D-printed electrodes lead to an increase in the mass correlation exponent as inertial flow effects dominate. The inertially enhanced mass transport yields mass transfer coefficients that exceed previously reported 3D-printed FTEs by 10 to 100 times, bringing 3D-printed FTE performance on par with conventional materials.

Enhanced neurite outgrowth on electrically conductive carbon aerogel substrates in the presence of an external electric field.

Previous works from our laboratory have firmly established that aerogels are a suitable substrate to elicit accelerated neurite extension. On non-conducting aerogels, in the presence of an externally-applied DC bias, neurons extended neurites which were preferentially aligned towards the anode. In this investigation, we sought to determine whether electrically-conductive carbon aerogels elicited a more robust alignment of neurites toward the anode than non-conductive aerogels due to the capacity of conductive aerogels to sustain a current, thereby providing a direct interface between neurons and the external electrical stimulus. To determine if this was the case, we plated PC12 neuronal cells on electrically conductive carbon aerolges derived from acetic acid-catalized resorcinol formaldehyde aerogels (ARF-CA) and subjected them to an external electric field. The voltages applied at the electrodes of the custom-built electro-stimulation chamber were 0 V, 15 V, and 30 V. For each voltage, the directionality and length of the neurites extended by PC12 cells were determined and compared to those observed when PC12 cells were plated on non-conductive aerogels subjected to the same voltage. The results show that the directionality of neurite extension was similar between conductive and non-conductive aerogels. A higher neurite length difference was observed on conductive aerogels with increasing voltage, 43% and 106% for 0-15 V and 0-30 V respectively, compared to non-conductive aerogels, 12% and 20%. These findings indicate that conductive carbon aerogels have a greater potential as scaffolds for nerve regeneration than non-conductive ones.

Refractive index matched polymeric and preceramic resins for height-scalable two-photon lithography.

Nanofabrication techniques that can generate large and complex 3D structures with nanoscale features are becoming increasingly important in the fields of biomedicine, micro-optics, and microfluidics. Direct laser writing via two-photon polymerization (DLW-TPP) is one such technique that relies on nonlinear absorption of light to form nanoscale 3D features. Although DLW-TPP provides the required nanoscale resolution, its built height is often limited to less than a millimetre. This height limitation is driven by the need to tightly focus the laser beam at arbitrary depths within the photopolymer. This requirement necessitates matching the photopolymer's refractive index to specific values but the required techniques have not been disseminated widely in the open scientific literature. To address this knowledge gap, we test two universal, different approaches to generate refractive index-matched polymeric and preceramic resins and demonstrate their performance by printing of fine submicron features in 3D structures as tall as 2.5 mm. Specifically, we achieve index-matching by mixing commercially-available resins or covalent modification of functional monomers. This work investigates the relationship of voxel shape to RI mismatch, and presents tuning of RI through mixing and covalent modification to a nonconventional material system of preceramic resin which has never been demonstrated before. We demonstrate the material flexibility by generating 3D silicon oxycarbide structures from preceramic resists while simultaneously eliminating the part-height limitation of conventional DLW-TPP.

3D-Printed Structure Boosts the Kinetics and Intrinsic Capacitance of Pseudocapacitive Graphene Aerogels.

The performance of pseudocapacitive electrodes at fast charging rates are typically limited by the slow kinetics of Faradaic reactions and sluggish ion diffusion in the bulk structure. This is particularly problematic for thick electrodes and electrodes highly loaded with active materials. Here, a surface-functionalized 3D-printed graphene aerogel (SF-3D GA) is presented that achieves not only a benchmark areal capacitance of 2195 mF cm-2 at a high current density of 100 mA cm-2 but also an ultrahigh intrinsic capacitance of 309.1 µF cm-2 even at a high mass loading of 12.8 mg cm-2 . Importantly, the kinetic analysis reveals that the capacitance of SF-3D GA electrode is primarily (93.3%) contributed from fast kinetic processes. This is because the 3D-printed electrode has an open structure that ensures excellent coverage of functional groups on carbon surface and facilitates the ion accessibility of these surface functional groups even at high current densities and large mass loading/electrode thickness. An asymmetric device assembled with SF-3D GA as anode and 3D-printed GA decorated with MnO2 as cathode achieves a remarkable energy density of 0.65 mWh cm-2 at an ultrahigh power density of 164.5 mW cm-2 , outperforming carbon-based supercapacitors operated at the same power density.

Negative Additive Manufacturing of Complex Shaped Boron Carbides.

Boron carbide (B4C) is one of the hardest materials in existence. However, this attractive property also limits its machineability into complex shapes for high wear, high hardness, and lightweight material applications such as armors. To overcome this challenge, negative additive manufacturing (AM) is employed to produce complex geometries of boron carbides at various length scales. Negative AM first involves gelcasting a suspension into a 3D-printed plastic mold. The mold is then dissolved away, leaving behind a green body as a negative copy. Resorcinol-formaldehyde (RF) is used as a novel gelling agent because unlike traditional hydrogels, there is little to no shrinkage, which allows for extremely complex molds to be used. Furthermore, this gelling agent can be pyrolyzed to leave behind ~50 wt% carbon, which is a highly effective sintering aid for B4C. Due to this highly homogenous distribution of in situ carbon within the B4C matrix, less than 2% porosity can be achieved after sintering. This protocol highlights in detail the methodology for creating near fully dense boron carbide parts with highly complex geometries.