Synthetic growth by self-lubricated photopolymerization and extrusion inspired by plants and fungi.

Many natural organisms, such as fungal hyphae and plant roots, grow at their tips, enabling the generation of complex bodies composed of natural materials as well as dexterous movement and exploration. Tip growth presents an exemplary process by which materials synthesis and actuation are coupled, providing a blueprint for how growth could be realized in a synthetic system. Herein, we identify three underlying principles essential to tip-based growth of biological organisms: a fluid pressure driving force, localized polymerization for generating structure, and fluid-mediated transport of constituent materials. In this work, these evolved features inspire a synthetic materials growth process called extrusion by self-lubricated interface photopolymerization (E-SLIP), which can continuously fabricate solid profiled polymer parts with tunable mechanical properties from liquid precursors. To demonstrate the utility of E-SLIP, we create a tip-growing soft robot, outline its fundamental governing principles, and highlight its capabilities for growth at speeds up to 12 cm/min and lengths up to 1.5 m. This growing soft robot is capable of executing a range of tasks, including exploration, burrowing, and traversing tortuous paths, which highlight the potential for synthetic growth as a platform for on-demand manufacturing of infrastructure, exploration, and sensing in a variety of environments.

The colloidal nature of complex fluids enhances bacterial motility.

The natural habitats of microorganisms in the human microbiome, ocean and soil ecosystems are full of colloids and macromolecules. Such environments exhibit non-Newtonian flow properties, drastically affecting the locomotion of microorganisms1-5. Although the low-Reynolds-number hydrodynamics of swimming flagellated bacteria in simple Newtonian fluids has been well developed6-9, our understanding of bacterial motility in complex non-Newtonian fluids is less mature10,11. Even after six decades of research, fundamental questions about the nature and origin of bacterial motility enhancement in polymer solutions are still under debate12-23. Here we show that flagellated bacteria in dilute colloidal suspensions display quantitatively similar motile behaviours to those in dilute polymer solutions, in particular a universal particle-size-dependent motility enhancement up to 80% accompanied by a strong suppression of bacterial wobbling18,24. By virtue of the hard-sphere nature of colloids, whose size and volume fraction we vary across experiments, our results shed light on the long-standing controversy over bacterial motility enhancement in complex fluids and suggest that polymer dynamics may not be essential for capturing the phenomenon12-23. A physical model that incorporates the colloidal nature of complex fluids quantitatively explains bacterial wobbling dynamics and mobility enhancement in both colloidal and polymeric fluids. Our findings contribute to the understanding of motile behaviours of bacteria in complex fluids, which are relevant for a wide range of microbiological processes25 and for engineering bacterial swimming in complex environments26,27.

Band Gap Tuning of Films of Undoped ZnO Nanocrystals by Removal of Surface Groups.

Transparent conductive oxides (TCOs) are widely used in optoelectronic devices such as flat-panel displays and solar cells. A significant optical property of TCOs is their band gap, which determines the spectral range of the transparency of the material. In this study, a tunable band gap range from 3.35 eV to 3.53 eV is achieved for zinc oxide (ZnO) nanocrystals (NCs) films synthesized by nonthermal plasmas through the removal of surface groups using atomic layer deposition (ALD) coating of Al2O3 and intense pulsed light (IPL) photo-doping. The Al2O3 coating is found to be necessary for band gap tuning, as it protects ZnO NCs from interactions with the ambient and prevents the formation of electron traps. With respect to the solar spectrum, the 0.18 eV band gap shift would allow ~4.1% more photons to pass through the transparent layer, for instance, into a CH3NH3PbX3 solar cell beneath. The mechanism of band gap tuning via photo-doping appears to be related to a combination of the Burstein-Moss (BM) and band gap renormalization (BGN) effects due to the significant number of electrons released from trap states after the removal of hydroxyl groups. The BM effect shifts the conduction band edge and enlarges the band gap, while the BGN effect narrows the band gap.

Capillary Flow with Evaporation in Open Rectangular Microchannels.

Numerous applications rely upon capillary flow in microchannels for successful operation including lab-on-a-chip devices, porous media flows, and printed electronics manufacturing. Open microchannels often appear in these applications, and evaporation of the liquid can significantly affect its flow. In this work, we develop a Lucas-Washburn-type one-dimensional model that incorporates the effects of concentration-dependent viscosity and uniform evaporation on capillary flow in channels of a rectangular cross section. The model yields predictions of the time evolution of the liquid front down the length of the microchannel. For the case where evaporation is absent, prior studies have demonstrated better agreement between model predictions and experimental observations in low-viscosity liquids when using a no-slip rather than a no-stress boundary condition at the upper liquid-air interface. However, flow visualization experiments conducted in this work suggest the absence of a rigidified liquid-air interface. The use of the no-stress condition results in overestimation of the time evolution of the liquid front, which appears to be due to underestimation of the viscous forces from (i) the upper and front meniscus morphology, (ii) dynamic contact angle effects, and (iii) surface roughness, none of which are accounted for in the model. When high-viscosity liquids are considered, the large bulk viscosity is found to suppress these factors, resulting in better agreement between model predictions using the no-stress condition and experiments. Model predictions are also compared to prior experiments involving poly(vinyl alcohol) in the presence of evaporation by using the evaporation rate as a fitting parameter. Scaling relationships obtained from the model for the dependence of the final liquid-front position and total flow time on the channel dimensions and rate of uniform evaporation are found to be in good agreement with experimental observations.

Capillary Coatings: Flow and Drying Dynamics in Open Microchannels.

Capillary flow and drying of polymer solutions in open microchannels are explored over time scales spanning seven orders of magnitude: from capillary filling (10-3-10 s) to the formation of a dry thin film (a "capillary coating"; 102-103 s). During capillary filling, drying-induced changes (increased solids content and viscosity) generate microscale pinning events that impede contact line motion. Three unique types of pinning are identified and characterized, each defined by the specific location(s) along the contact line at which pinning is induced. Drying is shown to ultimately pin the contact line permanently, and the associated total flow distances and times are revealed to be strong functions of channel width and drying rate. In general, lower drying rates coupled with intermediate channel widths are found to be most conducive to longer flow distances and times. After the advancing contact line permanently pins, internal flows driven by uneven evaporation rates continue to drive polymer to the contact line. This phenomenon promotes a local accumulation of solids and persists until all motion is arrested by drying. The effects of channel width and drying rate are investigated at each stage of this capillary coating process. These results are then applied to case studies of two functional inks commonly used in printed electronics fabrication: a PEDOT:PSS (poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate)) ink and a graphene ink. Although drying is shown to permanently arrest flow in both inks, both systems exhibit an increased resistance to pinning unexplained by mechanisms identified in aqueous polymer systems. Instead, arguments based on chemistry, particle size, and rheology are used to explain their novel behavior. These case studies provide insight into how functional inks can be better designed to optimize flow distances and maximize overall dry film uniformity in capillary coatings.

ZnO Nanocrystal Networks Near the Insulator-Metal Transition: Tuning Contact Radius and Electron Density with Intense Pulsed Light.

Networks of ligand-free semiconductor nanocrystals (NCs) offer a valuable combination of high carrier mobility and optoelectronic properties tunable via quantum confinement. In principle, maximizing carrier mobility entails crossing the insulator-metal transition (IMT), where carriers become delocalized. A recent theoretical study predicted that this transition occurs at nρ3 ≈ 0.3, where n is the carrier density and ρ is the interparticle contact radius. In this work, we satisfy this criterion in networks of plasma-synthesized ZnO NCs by using intense pulsed light (IPL) annealing to tune n and ρ independently. IPL applied to as-deposited NCs increases ρ by inducing sintering, and IPL applied after the NCs are coated with Al2O3 by atomic layer deposition increases n by removing electron-trapping surface hydroxyls. This procedure does not substantially alter NC size or composition and is potentially applicable to a wide variety of nanomaterials. As we increase nρ3 to at least twice the predicted critical value, we observe conductivity scaling consistent with arrival at the critical region of a continuous quantum phase transition. This allows us to determine the critical behavior of the dielectric constant and electron localization length at the IMT. However, our samples remain on the insulating side of the critical region, which suggests that the critical value of nρ3 may in fact be significantly higher than 0.3.

High-Resolution Transfer Printing of Graphene Lines for Fully Printed, Flexible Electronics.

Pristine graphene inks show great promise for flexible printed electronics due to their high electrical conductivity and robust mechanical, chemical, and environmental stability. While traditional liquid-phase printing methods can produce graphene patterns with a resolution of ∼30 µm, more precise techniques are required for improved device performance and integration density. A high-resolution transfer printing method is developed here capable of printing conductive graphene patterns on plastic with line width and spacing as small as 3.2 and 1 µm, respectively. The core of this method lies in the design of a graphene ink and its integration with a thermally robust mold that enables annealing at up to ∼250 °C for precise, high-performance graphene patterns. These patterns exhibit excellent electrical and mechanical properties, enabling favorable operation as electrodes in fully printed electrolyte-gated transistors and inverters with stable performance even following cyclic bending to a strain of 1%. The high resolution coupled with excellent control over the line edge roughness to below 25 nm enables aggressive scaling of transistor dimensions, offering a compelling route for the scalable manufacturing of flexible nanoelectronic devices.

Modulus- and Surface-Energy-Tunable Thiol-ene for UV Micromolding of Coatings.

Micromolding of UV-curable materials is a patterning method to fabricate microstructured surfaces that is an additive manufacturing process fully compatible with roll-to-roll systems. The development of micromolding for mass production remains a challenge because of the multifaceted demands of UV curable materials and the risk of demolding-related defects, particularly when patterning high-aspect-ratio features. In this research, a robust micromolding approach is demonstrated that integrates thiol-ene polymerization and UV LED curing. The moduli of cured thiol-ene coatings were tuned over 2 orders of magnitude by simply adjusting the acrylate concentration of a coating formulation, the curing completed in all cases within 10 s of LED exposure. Densely packed 50-µm-wide gratings were faithfully replicated in coatings ranging from soft materials to stiff highly cross-linked networks. Further, surface energy was modified with a fluorinated polymer, achieving a surface energy reduction of more than a half at a loading of 1 wt %, and enabling tall (100 µm) defect-free patterns to be attained. The demolding strengths of microstructured coatings were compared using quantitative peel testing, showing its decrease with decreasing surface energy, coating modulus, and grating height. This micromolding process, combining tunability in thermomechanical and surface properties, makes thiol-ene microstructured coatings attractive candidates for roll-to-roll manufacture. As a demonstration of the utility of the process, superhydrophobic surfaces are prepared using the system modified by the fluorinated polymer.

Copper-Zinc-Tin-Sulfide Thin Films via Annealing of Ultrasonic Spray Deposited Nanocrystal Coatings.

Thin polycrystalline films of the solar absorber copper-zinc-tin-sulfide (CZTS) were formed by annealing coatings deposited on molybdenum-coated soda lime glass via ultrasonic spraying of aerosol droplets from colloidal CZTS nanocrystal dispersions. Production of uniform continuous nanocrystal coatings with ultrasonic spraying requires that the evaporation time is longer than the aerosol flight time from the spray nozzle to the substrate such that the aerosol droplets still have low enough viscosity to smooth the impact craters that form on the coating surface. In this work, evaporation was slowed by adding a high boiling point cosolvent, cyclohexanone, to toluene as the dispersing liquid. We analyzed, quantitatively, the effects of the solvent composition on the aerosol and coating drying dynamics using an aerosol evaporation model. Annealing coatings in sulfur vapor converts them into polycrystalline films with micrometer size grains, but the grains form continuous films only when Na is present during annealing to enhance grain growth. Continuous films are easier to form when the average nanocrystal size is 15 nm: using larger nanocrystals (e.g., 20 nm) sacrifices film continuity.

Dynamics of Capillary-Driven Flow in 3D Printed Open Microchannels.

Microchannels have applications in microfluidic devices, patterns for micromolding, and even flexible electronic devices. Three-dimensional (3D) printing presents a promising alternative manufacturing route for these microchannels due to the technology's relative speed and the design freedom it affords its users. However, the roughness of 3D printed surfaces can significantly influence flow dynamics inside of a microchannel. In this work, open microchannels are fabricated using four different 3D printing techniques: fused deposition modeling (FDM), stereolithography (SLA), selective laser sintering, and multi jet modeling. Microchannels printed with each technology are evaluated with respect to their surface roughness, morphology, and how conducive they are to spontaneous capillary filling. Based on this initial assessment, microchannels printed with FDM and SLA are chosen as models to study spontaneous, capillary-driven flow dynamics in 3D printed microchannels. Flow dynamics are investigated over short (∼10-3 s), intermediate (∼1 s), and long (∼102 s) time scales. Surface roughness causes a start-stop motion down the channel due to contact line pinning, while the cross-sectional shape imparted onto the channels during the printing process is shown to reduce the expected filling velocity. A significant delay in the onset of Lucas-Washburn dynamics (a long-time equilibrium state where meniscus position advances proportionally to the square root of time) is also observed. Flow dynamics are assessed as a function of printing technology, print orientation, channel dimensions, and liquid properties. This study provides the first in-depth investigation of the effect of 3D printing on microchannel flow dynamics as well as a set of rules on how to account for these effects in practice. The extension of these effects to closed microchannels and microchannels fabricated with other 3D printing technologies is also discussed.

Dynamic self-assembly of charged colloidal strings and walls in simple fluid flows.

Colloidal particles can self-assemble into various ordered structures in fluid flows that have potential applications in biomedicine, materials synthesis and encryption. These dynamic processes are also of fundamental interest for probing the general principles of self-assembly under non-equilibrium conditions. Here, we report a simple microfluidic experiment, where charged colloidal particles self-assemble into flow-aligned 1D strings with regular particle spacing near a solid boundary. Using high-speed confocal microscopy, we systematically investigate the influence of flow rates, electrostatics and particle polydispersity on the observed string structures. By studying the detailed dynamics of stable flow-driven particle pairs, we quantitatively characterize interparticle interactions. Based on the results, we construct a simple model that explains the intriguing non-equilibrium self-assembly process. Our study shows that the colloidal strings arise from a delicate balance between attractive hydrodynamic coupling and repulsive electrostatic interaction between particles. Finally, we demonstrate that, with the assistance of transverse electric fields, a similar mechanism also leads to the formation of 2D colloidal walls.

Toughening Glassy Poly(lactide) with Block Copolymer Micelles.

Poly(lactide) (PLA), a compostable bioderived polyester, can be produced at a cost and scale that makes it an attractive replacement for nondegradable petroleum-derived thermoplastics. However, pristine PLA is brittle and unsuitable for use in applications where high impact strength and ductility are required. In this work we demonstrate that poly(l-lactide) (PLLA) in the glassy state can be toughened significantly via addition of an amphiphilic diblock polymer. Notably, a PLLA blend containing only 5 wt% poly(ethylene oxide)-b-poly(butylene oxide) (PEO-PBO) exhibited tensile toughness and notched Izod impact strength over an order of magnitude higher than neat amorphous PLLA without a significant reduction in transparency or elastic modulus. For a series of PLLA blends containing PEO-PBO of fixed composition (∼70% volume fraction PBO), the toughness was inversely related to the molar mass of the added modifier with the highest toughness observed for the blend containing the smallest diblock (∼7 kg/mol). Interestingly, at fixed composition and molar mass poly(l-lactide)-b-poly(butylene oxide) (PLLA-PBO) exhibited a substantial but reduced toughening efficiency compared to PEO-PBO. We attribute this difference to a change in the solubility parameter of the amphiphilc block. Using TEM, we show that the greatest toughening is observed when the diblock modifier forms small cylindrical micelles that are well dispersed in the PLLA matrix. This morphology is facilitated by a negative Flory-Huggins interaction parameter (χ) between PEO and PLLA. These insights suggest a new and versatile strategy for the facile and efficient toughening of brittle thermoplastics.

All-Printed, Foldable Organic Thin-Film Transistors on Glassine Paper.

All-printed, foldable organic thin-film transistors are demonstrated on glassine paper with a combination of advanced materials and processing techniques. Glassine paper provides a suitable surface for high-performance printing methods, while graphene electrodes and an ion-gel gate dielectric enable robust stability over 100 folding cycles. Altogether, this study features a practical platform for low-cost, large-area, and foldable electronics.

Wettability Contrast Gravure Printing.

Silicon gravure patterns are engineered to have cells that are wettable and lands that are not wettable by aqueous inks. This strategy allows excess ink on the lands to be removed without using a doctor blade. Using an aqueous silica ink, continuous lines as narrow as 1.2 µm with 1.5 µm space are gravure printed.

Screen Printing of Highly Loaded Silver Inks on Plastic Substrates Using Silicon Stencils.

Screen printing is a potential technique for mass-production of printed electronics; however, improvement in printing resolution is needed for high integration and performance. In this study, screen printing of highly loaded silver ink (77 wt %) on polyimide films is studied using fine-scale silicon stencils with openings ranging from 5 to 50 µm wide. This approach enables printing of high-resolution silver lines with widths as small as 22 µm. The printed silver lines on polyimide exhibit good electrical properties with a resistivity of 5.5×10(-6) Ω cm and excellent bending tolerance for bending radii greater than 5 mm (tensile strains less than 0.75%).

Formation of Copper Zinc Tin Sulfide Thin Films from Colloidal Nanocrystal Dispersions via Aerosol-Jet Printing and Compaction.

A three-step method to create dense polycrystalline semiconductor thin films from nanocrystal liquid dispersions is described. First, suitable substrates are coated with nanocrystals using aerosol-jet printing. Second, the porous nanocrystal coatings are compacted using a weighted roller or a hydraulic press to increase the coating density. Finally, the resulting coating is annealed for grain growth. The approach is demonstrated for making polycrystalline films of copper zinc tin sulfide (CZTS), a new solar absorber composed of earth-abundant elements. The range of coating morphologies accessible through aerosol-jet printing is examined and their formation mechanisms are revealed. Crack-free albeit porous films are obtained if most of the solvent in the aerosolized dispersion droplets containing the nanocrystals evaporates before they impinge on the substrate. In this case, nanocrystals agglomerate in flight and arrive at the substrate as solid spherical agglomerates. These porous coatings are mechanically compacted, and the density of the coating increases with compaction pressure. Dense coatings annealed in sulfur produce large-grain (>1 µm) polycrystalline CZTS films with microstructure suitable for thin-film solar cells.

Oriented MFI Membranes by Gel-Less Secondary Growth of Sub-100 nm MFI-Nanosheet Seed Layers.

A zeolite membrane fabrication process combining 2D-zeolite nanosheet seeding and gel-free secondary growth is described. This process produces selective molecular sieve films that are as thin as 100 nm and exhibit record high permeances for xylene- and butane-isomers.

High-resolution, high-aspect ratio conductive wires embedded in plastic substrates.

A novel method is presented to fabricate high-resolution, high-aspect ratio metal wires embedded in a plastic substrate for flexible electronics applications. In a sequential process, high-resolution channels connected to low-resolution reservoirs are first created in a thermosetting polymer by imprint lithography. A reactive Ag ink is then inkjet-printed into the reservoirs and wicked into the channels by capillary forces. These features serve as a seed layer for copper deposition inside the channels via electroless plating. Highly conductive wires (>50% bulk metal) with minimum line width and spacing of 2 and 4 µm, respectively, and an aspect ratio of 0.6 are obtained. The embedded wires exhibit good mechanical flexibility, with minimal degradation in electrical performance after thousands of bending cycles.

High-resolution patterning of graphene by screen printing with a silicon stencil for highly flexible printed electronics.

High-resolution screen printing of pristine graphene is introduced for the rapid fabrication of conductive lines on flexible substrates. Well-defined silicon stencils and viscosity-controlled inks facilitate the preparation of high-quality graphene patterns as narrow as 40 µm. This strategy provides an efficient method to produce highly flexible graphene electrodes for printed electronics.