Approaching Standardization: Mechanical Material Testing of Macroscopic Two-Photon Polymerized Specimens.

Two-photon polymerization (2PP) is becoming increasingly established as additive manufacturing technology for microfabrication due to its high-resolution and the feasibility of generating complex parts. Until now, the high resolution of 2PP is also its bottleneck, as it limited throughput and therefore restricted the application to the production of microparts. Thus, mechanical properties of 2PP materials can only be characterized using nonstandardized specialized microtesting methods. Due to recent advances in 2PP technology, it is now possible to produce parts in the size of several millimeters to even centimeters, finally permitting the fabrication of macrosized testing specimens. Besides suitable hardware systems, 2PP materials exhibiting favorable mechanical properties that allow printing of up-scaled parts are strongly demanded. In this work, the up-scalability of three different photopolymers is investigated using a high-throughput 2PP system and low numerical aperture optics. Testing specimens in the cm-range are produced and tested with common or even standardized material testing methods available in conventionally equipped polymer testing labs. Examples of the characterization of mechanical, thermo-mechanical, and fracture properties of 2PP processed materials are shown. Additionally, aspects such as postprocessing and aging are investigated. This lays a foundation for future expansion of the 2PP technology to broader industrial application.

AI-Enabled Materials Design of Non-Periodic 3D Architectures With Predictable Direction-Dependent Elastic Properties.

Natural porous materials have exceptional properties-for example, light weight, mechanical resilience, and multi-functionality. Efforts to imitate their properties in engineered structures have limited success. This, in part, is caused by the complexity of multi-phase materials composites and by the lack of quantified understanding of each component's role in overall hierarchy. This challenge is twofold: 1) computational. because non-periodicity and defects render constructing design guidelines between geometries and mechanical properties complex and expensive and 2) experimental. because the fabrication and characterization of complex, often hierarchical and non-periodic 3D architectures is non-trivial.

Carbon-Related Quantum Emitter in Hexagonal Boron Nitride with Homogeneous Energy and 3-Fold Polarization.

Most hexagonal boron nitride (hBN) single-photon emitters (SPEs) studied to date suffer from variable emission energy and unpredictable polarization, two crucial obstacles to their application in quantum technologies. Here, we report an SPE in hBN with an energy of 2.2444 ± 0.0013 eV created via carbon implantation that exhibits a small inhomogeneity of the emission energy. Polarization-resolved measurements reveal aligned absorption and emission dipole orientations with a 3-fold distribution, which follows the crystal symmetry. Photoluminescence excitation (PLE) spectroscopy results show the predictability of polarization is associated with a reproducible PLE band, in contrast with the non-reproducible bands found in previous hBN SPE species. Photon correlation measurements are consistent with a three-level model with weak coupling to a shelving state. Our ab initio excited-state calculations shed light on the atomic origin of this SPE defect, which consists of a pair of substitutional carbon atoms located at boron and nitrogen sites separated by a hexagonal unit cell.

Microstructure-driven mechanical and electromechanical phenomena in additively manufactured nanocrystalline zinc oxide.

Advances in nanoscale additive manufacturing (AM) offer great opportunities to expand nanotechnologies; however, the size effects in these printed remain largely unexplored. Using bothin situnanomechanical and electrical experiments and molecular dynamics (MD) simulations, this study investigates additively manufactured nano-architected nanocrystalline ZnO (nc-ZnO) with ∼7 nm grains and dimensions spanning 0.25-4µm. These nano-scale ceramics are fabricated through printing and subsequent burning of metal ion-containing hydrogels to produce oxide structures. Electromechanical behavior is shown to result from random ordering in the microstructure and can be modeled through a statistical treatment. A size effect in the failure behavior of AM nc-ZnO is also observed and characterized by the changes in deformation behavior and suppression of brittle failure. MD simulations provide insights to the role of grain boundaries and grain boundary plasticity on both electromechanical behavior and failure mechanisms in nc-ZnO. The frameworks developed in this paper extend to other AM nanocrystalline materials and provide quantification of microstructurally-drive limitations to precision in materials property design.

Suppressed Size Effect in Nanopillars with Hierarchical Microstructures Enabled by Nanoscale Additive Manufacturing.

Studies on mechanical size effects in nanosized metals unanimously highlight both intrinsic microstructures and extrinsic dimensions for understanding size-dependent properties, commonly focusing on strengths of uniform microstructures, e.g., single-crystalline/nanocrystalline and nanoporous, as a function of pillar diameters, D. We developed a hydrogel infusion-based additive manufacturing (AM) technique using two-photon lithography to produce metals in prescribed 3D-shapes with ∼100 nm feature resolution. We demonstrate hierarchical microstructures of as-AM-fabricated Ni nanopillars (D ∼ 130-330 nm) to be nanoporous and nanocrystalline, with d ∼ 30-50 nm nanograins subtending each ligament in bamboo-like arrangements and pores with critical dimensions comparable to d. In situ nanocompression experiments unveil their yield strengths, σ, to be ∼1-3 GPa, above single-crystalline/nanocrystalline counterparts in the D range, a weak size dependence, σ ∝ D-0.2, and localized-to-homogenized transition in deformation modes mediated by nanoporosity, uncovered by molecular dynamics simulations. This work highlights hierarchical microstructures on mechanical response in nanosized metals and suggests small-scale engineering opportunities through AM-enabled microstructures.

Knots are not for naught: Design, properties, and topology of hierarchical intertwined microarchitected materials.

Lightweight and tough engineered materials are often designed with three-dimensional hierarchy and interconnected structural members whose junctions are detrimental to their performance because they serve as stress concentrations for damage accumulation and lower mechanical resilience. We introduce a previously unexplored class of architected materials, whose components are interwoven and contain no junctions, and incorporate micro-knots as building blocks within these hierarchical networks. Tensile experiments, which show close quantitative agreements with an analytical model for overhand knots, reveal that knot topology allows a new regime of deformation capable of shape retention, leading to a ~92% increase in absorbed energy and an up to ~107% increase in failure strain compared to woven structures, along with an up to ~11% increase in specific energy density compared to topologically similar monolithic lattices. Our exploration unlocks knotting and frictional contact to create highly extensible low-density materials with tunable shape reconfiguration and energy absorption capabilities.

Metasurface-Enabled Holographic Lithography for Impact-Absorbing Nanoarchitected Sheets.

Nanoarchitected materials represent a class of structural meta-materials that utilze nanoscale features to achieve unconventional material properties such as ultralow density and high energy absorption. A dearth of fabrication methods capable of producing architected materials with sub-micrometer resolution over large areas in a scalable manner exists. A fabrication technique is presented that employs holographic patterns generated by laser exposure of phase metasurface masks in negative-tone photoresists to produce 30-40 µm-thick nanoarchitected sheets with 2.1 × 2.4 cm2 lateral dimensions and ≈500 nm-wide struts organized in layered 3D brick-and-mortar-like patterns to result in ≈50-70% porosity. Nanoindentation arrays over the entire sample area reveal the out-of-plane elastic modulus to vary between 300 MPa and 4 GPa, with irrecoverable post-elastic material deformation commencing via individual nanostrut buckling, densification within layers, shearing along perturbation perimeter, and tensile cracking. Laser induced particle impact tests (LIPIT) indicate specific inelastic energy dissipation of 0.51-2.61 MJ kg-1 , which is comparable to other high impact energy absorbing composites and nanomaterials, such as Kevlar/poly(vinyl butyral) (PVB) composite, polystyrene, and pyrolized carbon nanolattices with 23% relative density. These results demonstrate that holographic lithography offers a promising platform for scalable manufacturing of nanoarchitected materials with impact resistant capabilities.

Chemo-mechanical-microstructural coupling in the tarsus exoskeleton of the scorpion Scorpio palmatus.

The multiscale structure of biomaterials enables their exceptional mechanical robustness, yet the impact of each constituent at their relevant length scale remains elusive. We used SAXD analysis to expose the intact chitin-fiber architecture within the exoskeleton on a scorpion's claw, revealing varying orientations, including Bouligand and unidirectional regions different from other arthropod species. We uncovered the contribution of individual components' constituent behavior to its mechanical properties from the micro- to the nanoscale. At the microscale, in-situ micromechanical experiments were used to determine site-specific stiffness, strength, and failure of the biocomposite due to fiber orientation, while metal-crosslinking of proteins is characterized via fluorescence maps. At the constituent level, combined with FEA simulations, we uncovered the behavior of fiber-matrix deformation with fiber diameter <53.7 nm and protein modulus in the range 1.4-11 MPa. The unveiled microstructure-mechanics relationship sheds light on the evolved structural functionalities and constituents' interactions within the scorpion cuticle. STATEMENT OF SIGNIFICANCE: The pincer exoskeleton is a fundamental part of the scorpion's body due to its multifunctionality. Precise structural and compositional analysis within the hierarchy is paramount to understand the fundamentals of the mechanical properties of the composite exoskeleton. Here, we expose the intact chitin-fiber architecture of the pincer exoskeleton using nondestructive analysis. In-situ mechanical characterization was performed at nanometer levels within the exoskeleton hierarchy, which complemented with simulations, uncovered the elastic modulus of the protein matrix. Our findings confirm the presence and distribution of metal ions and their role as reinforcements in the protein matrix via ligand coordinate bonds. In future work, these findings can be of great potential to inspire the design of composite materials.

Enabling Durable Ultralow-k Capacitors with Enhanced Breakdown Strength in Density-Variant Nanolattices.

Ultralow-k materials used in high voltage devices require mechanical resilience and electrical and dielectric stability even when subjected to mechanical loads. Existing devices with organic polymers suffer from low thermal and mechanical stability while those with inorganic porous structures struggle with poor mechanical integrity. Recently, 3D hollow-beam nanolattices have emerged as promising candidates that satisfy these requirements. However, their properties are maintained for only five stress cycles at strains below 25%. Here, we demonstrate that alumina nanolattices with different relative density distributions across their height elicit a deterministic mechanical response concomitant with a 1.5-3.3 times higher electrical breakdown strength than nanolattices with uniform density. These density-variant nanolattices exhibit an ultralow-k of ≈1.2, accompanied by complete electric and dielectric stability and mechanical recoverability over 100 cyclic compressions to 62.5% strain. We explain the enhanced insulation and long-term cyclical stability by the bi-phase deformation where the lower-density region protects the higher-density region as it is compressed before the higher-density region, allowing to simultaneously possess high strength and ductility like composites. This study highlights the superior electrical performance of the bi-phase nanolattice with a single interface in providing stable conduction and maximum breakdown strength.

Deformation characteristics of solid-state benzene as a step towards understanding planetary geology.

Small organic molecules, like ethane and benzene, are ubiquitous in the atmosphere and surface of Saturn's largest moon Titan, forming plains, dunes, canyons, and other surface features. Understanding Titan's dynamic geology and designing future landing missions requires sufficient knowledge of the mechanical characteristics of these solid-state organic minerals, which is currently lacking. To understand the deformation and mechanical properties of a representative solid organic material at space-relevant temperatures, we freeze liquid micro-droplets of benzene to form ~10 µm-tall single-crystalline pyramids and uniaxially compress them in situ. These micromechanical experiments reveal contact pressures decaying from ~2 to ~0.5 GPa after ~1 µm-reduction in pyramid height. The deformation occurs via a series of stochastic (~5-30 nm) displacement bursts, corresponding to densification and stiffening of the compressed material during cyclic loading to progressively higher loads. Molecular dynamics simulations reveal predominantly plastic deformation and densified region formation by the re-orientation and interplanar shear of benzene rings, providing a two-step stiffening mechanism. This work demonstrates the feasibility of in-situ cryogenic nanomechanical characterization of solid organics as a pathway to gain insights into the geophysics of planetary bodies.

Additive manufacturing of micro-architected metals via hydrogel infusion.

Metal additive manufacturing (AM) enables the production of high value and high performance components1 with applications from aerospace2 to biomedical3 fields. Layer-by-layer fabrication circumvents the geometric limitations of traditional metalworking techniques, allowing topologically optimized parts to be made rapidly and efficiently4,5. Existing AM techniques rely on thermally initiated melting or sintering for part shaping, a costly and material-limited process6-8. We report an AM technique that produces metals and alloys with microscale resolution via vat photopolymerization (VP). Three-dimensional-architected hydrogels are infused with metal precursors, then calcined and reduced to convert the hydrogel scaffolds into miniaturized metal replicas. This approach represents a paradigm shift in VP; the material is selected only after the structure is fabricated. Unlike existing VP strategies, which incorporate target materials or precursors into the photoresin during printing9-11, our method does not require reoptimization of resins and curing parameters for different materials, enabling quick iteration, compositional tuning and the ability to fabricate multimaterials. We demonstrate AM of metals with critical dimensions of approximately 40 µm that are challenging to fabricate by using conventional processes. Such hydrogel-derived metals have highly twinned microstructures and unusually high hardness, providing a pathway to create advanced metallic micromaterials.

Tailoring the Desorption Behavior of Hygroscopic Gels for Atmospheric Water Harvesting in Arid Climates.

The ubiquitous nature of atmospheric moisture makes it a significant water resource available at any geographical location. Atmospheric water harvesting (AWH) technology, which extracts moisture from the ambient air to generate clean water, is a promising strategy to realize decentralized water production. The high water uptake by salt-based sorbents makes them attractive for AWH, especially in arid environments. However, they often have relatively high desorption heat, rendering water release an energy-intensive process. A  LiCl-incorporating polyacrylamide hydrogel (PAM-LiCl) capable of effective moisture harvesting from arid environments is proposed. The interactions between the hydrophilic hydrogel network and the captured water generate more free and weakly bonded water, significantly lowering the desorption heat compared with conventional neat salt sorbents. Benefiting from the affinity for swelling of the polymer backbones, the developed PAM-LiCl achieves a high water uptake of ≈1.1 g g-1 at 20% RH with fast sorption kinetics of ≈0.008 g g-1  min-1  and further demonstrates a daily water yield up to ≈7 g g-1 at this condition. These findings provide a new pathway for the synthesis of materials with efficient water absorption/desorption properties, to reach energy-efficient water release for AWH in arid climates.

Responsive materials architected in space and time.

Rationally designed architected materials have attained previously untapped territories in materials property space. The properties and behaviours of architected materials need not be stagnant after fabrication; they can be encoded with a temporal degree of freedom such that they evolve over time. In this Review, we describe the variety of materials architected in both space and time, and their responses to various stimuli, including mechanical actuation, changes in temperature and chemical environment, and variations in electromagnetic fields. We highlight the additive manufacturing methods that can precisely prescribe complex geometries and local inhomogeneities to make such responsiveness possible. We discuss the emergent physics phenomena observed in architected materials that are analogous to those in classical materials, such as the formation and behaviour of defects, phase transformations and topologically protected properties. Finally, we offer a perspective on the future of architected materials that have a degree of intelligence through mechanical logic and artificial neural networks.

Dispersion Mapping in 3-Dimensional Core-Shell Photonic Crystal Lattices Capable of Negative Refraction in the Mid-Infrared.

Engineering of the dispersion properties of a photonic crystal (PhC) opens a new paradigm for the design and function of PhC devices. Exploiting the dispersion properties of PhCs allows control over wave propagation within a PhC. We describe the design, fabrication, and experimental observation of photonic bands for 3D PhCs capable of negative refraction in the mid-infrared. Band structure and equifrequency contours were calculated to inform the design of 3D polymer-germanium core-shell PhCs, which were fabricated using two-photon lithography direct laser writing and sputtering. We successfully characterized a polymer-Ge core-shell lattice and mapped its band structure, which we then used to calculate the PhC refraction behavior. An analysis of wave propagation revealed that this 3D core-shell PhC refracts light negatively and possesses an effective negative index of refraction in the experimentally observed region. These results suggest that architected nanolattices have the potential to serve as new optical components and devices across infrared frequencies.

Failure Mechanisms in Vertically Aligned Dense Nanowire Arrays.

Nanowires are an increasingly prevalent class of nanomaterials in composites and devices, with arrays and other complex geometries used in various applications. Little investigation has been done regarding the mechanical behavior of micron-sized nanowire structures. We conduct in situ microcompression experiments on vertically aligned dense microbundles of 300 nm diameter single-crystalline zinc oxide nanowires to gain insights into their structural failure. Experiments demonstrate that bundles containing approximately 10-130 nanowires experience two failure regimes: (1) localized noncatastrophic interfacial splitting and (2) global structural failure. Utilizing Weibull statistics and experimental results, we develop a technique for analyzing flaw distribution and use it to predict the expected range of bundle failure stress. This analysis provides guidelines for nanowire arrays' susceptibility to failure, sensitivity to flaw size, interfacial interactions of constituents, and degree of alignment. This work develops insights to understand and predict fundamental failure mechanisms in highly aligned, dense structures.

3D-Printed Drug Capture Materials Based on Genomic DNA Coatings.

The toxic side effects of chemotherapy have long limited its efficacy, prompting expensive and long-drawn efforts to develop more targeted cancer therapeutics. An alternative approach to mitigate off-target toxicity is to develop a device that can sequester chemotherapeutic agents from the veins that drain the target organ before they enter systemic circulation. This effectively localizes the chemotherapy to the target organ, minimizing any hazardous side effects. 3D printing is ideal for fabricating these devices, as the geometric control afforded allows us to precisely dictate its hemodynamic performance in vivo. However, the existing materials compatible with 3D printing do not have drug-binding capabilities. Here, we report the stable coating of genomic DNA on a 3D-printed structure for the capture of doxorubicin. Genomic DNA is an effective chemotherapeutic-agent capture material due to the intrinsic DNA-targeting mechanism of action of these drugs. Stable DNA coatings were achieved through a combination of electrostatic interactions and ultraviolet C (UVC, 254 nm) cross-linking. These UVC cross-linked DNA coatings were extremely stable-leaching on average 100 pg of genomic DNA per mm2 of 3D-printed structure over a period of 30 min. In vitro studies of these materials in phosphate buffered saline and human serum demonstrated that they were able to capture, on average, 72 and 60 ng of doxorubicin per mm2 of structure, respectively. The stability and efficacy of these genomic DNA-coated 3D-printed materials represent a significant step forward towards the translation of these devices to clinical applications for the potential improvement of chemotherapy treatment.

Supersonic impact resilience of nanoarchitected carbon.

Architected materials with nanoscale features have enabled extreme combinations of properties by exploiting the ultralightweight structural design space together with size-induced mechanical enhancement at small scales. Apart from linear waves in metamaterials, this principle has been restricted to quasi-static properties or to low-speed phenomena, leaving nanoarchitected materials under extreme dynamic conditions largely unexplored. Here, using supersonic microparticle impact experiments, we demonstrate extreme impact energy dissipation in three-dimensional nanoarchitected carbon materials that exhibit mass-normalized energy dissipation superior to that of traditional impact-resistant materials such as steel, aluminium, polymethyl methacrylate and Kevlar. In-situ ultrahigh-speed imaging and post-mortem confocal microscopy reveal consistent mechanisms such as compaction cratering and microparticle capture that enable this superior response. By analogy to planetary impact, we introduce predictive tools for crater formation in these materials using dimensional analysis. These results substantially uncover the dynamic regime over which nanoarchitecture enables the design of ultralightweight, impact-resistant materials that could open the way to design principles for lightweight armour, protective coatings and blast-resistant shields for sensitive electronics.

Hydrogel-based Additive Manufacturing of Lithium Cobalt Oxide.

Three-dimensional (3D) multicomponent metal oxides with complex architectures could enable previously impossible energy storage devices, particularly lithium-ion battery (LIB) electrodes with fully controllable form factors. Existing additive manufacturing approaches for fabricating 3D multicomponent metal oxides rely on particle-based or organic-inorganic binders, which are limited in their resolution and chemical composition, respectively. In this work, aqueous metal salt solutions are used as metal precursors to circumvent these limitations, and provide a platform for 3D printing multicomponent metal oxides. As a proof-of-concept, architected lithium cobalt oxide (LCO) structures are fabricated by first synthesizing a homogenous lithium and cobalt nitrate aqueous photoresin, and then using it with digital light processing printing to obtain lithium and cobalt ion containing hydrogels. The 3D hydrogels are calcined to obtain micro-porous self-similar LCO architectures with a resolution of ~100µm. These free-standing, binder- and conductive additive-free LCO structures are integrated as cathodes into LIBs, and exhibit electrochemical capacity retention of 76% over 100 cycles at C/10. This facile approach to fabricating 3D LCO structures can be extended to other materials by tailoring the identity and stoichiometry of the metal salt solutions used, providing a versatile method for the fabrication of multicomponent metal oxides with complex 3D architectures.

All-day fresh water harvesting by microstructured hydrogel membranes.

Solar steam water purification and fog collection are two independent processes that could enable abundant fresh water generation. We developed a hydrogel membrane that contains hierarchical three-dimensional microstructures with high surface area that combines both functions and serves as an all-day fresh water harvester. At night, the hydrogel membrane efficiently captures fog droplets and directionally transports them to a storage vessel. During the daytime, it acts as an interfacial solar steam generator and achieves a high evaporation rate of 3.64 kg m-2 h-1 under 1 sun enabled by improved thermal/vapor flow management. With a homemade rooftop water harvesting system, this hydrogel membrane can produce fresh water with a daily yield of ~34 L m-2 in an outdoor test, which demonstrates its potential for global water scarcity relief.

Nanofibril-mediated fracture resistance of bone.

Natural hard composites like human bone possess a combination of strength and toughness that exceeds that of their constituents and of many engineered composites. This augmentation is attributed to their complex hierarchical structure, spanning multiple length scales; in bone, characteristic dimensions range from nanoscale fibrils to microscale lamellae to mesoscale osteons and macroscale organs. The mechanical properties of bone have been studied, with the understanding that the isolated microstructure at micro- and nano-scales gives rise to superior strength compared to that of whole tissue, and the tissue possesses an amplified toughness relative to that of its nanoscale constituents. Nanoscale toughening mechanisms of bone are not adequately understood at sample dimensions that allow for isolating salient microstructural features, because of the challenge of performing fracture experiments on small-sized samples. We developed anin situthree-point bend experimental methodology that probes site-specific fracture behavior of micron-sized specimens of hard material. Using this, we quantify crack initiation and growth toughness of human trabecular bone with sharp fatigue pre-cracks and blunt notches. Our findings indicate that bone with fatigue cracks is two times tougher than that with blunt cracks.In situdata-correlated electron microscopy videos reveal this behavior arises from crack-bridging by nanoscale fibril structure. The results reveal a transition between fibril-bridging (∼1µm) and crack deflection/twist (∼500µm) as a function of length-scale, and quantitatively demonstrate hierarchy-induced toughening in a complex material. This versatile approach enables quantifying the relationship between toughness and microstructure in various complex material systems and provides direct insight for designing biomimetic composites.