Direct write micro/nano optical fibers by near-field melt electrospinning.

A simple fabrication method of micro/nano-optical fibers (MNOFs) based on near-field melt electrospinning (NMES) is proposed in this Letter. Single fibers with diameters ranging from 500 nm to 6 µm were directly written by near-field electrospinning of molten poly(methyl methacrylate) (PMMA). The morphology and transmission characteristics of single PMMA MNOFs were experimentally measured. The results showed that PMMA MNOFs have the advantages of smooth surfaces, uniform diameters, and low loss. As an example of one-step fabrication for MNOF devices, a planar helical MNOF structure was directly written and optically characterized. To demonstrate the versatility of the NMES process, in combination with the microfluidic technique, a liquid refractive index-sensing chip was fabricated and tested. Our results demonstrate that the proposed fabrication method has strong potential in the direct writing of patterned optical devices and heterogeneous integrated devices.

Conformal Fabrication of Thick Film Platinum Strain Gauge Via Error Regulation Strategies for In Situ High-Temperature Strain Detection.

Monitoring high-temperature strain on curved components in harsh environments is a challenge for a wide range of applications, including in aircraft engines, gas turbines, and hypersonic vehicles. Although there are significant improvements in the preparation of high-temperature piezoresistive film on planar surfaces using 3D printing methods, there are still difficulties with poor surface compatibility and high-temperature strain testing on curved surfaces. Herein, a conformal direct ink writing (CDIW) system coupled with an error feedback regulation strategy was used to fabricate high-precision, thick films on curved surfaces. This strategy enabled the maximum amount of error in the distance between the needle and the substrate on a curved surface to be regulated from 155 to 4 µm. A conformal Pt thick-film strain gauge (CPTFSG) with a room-temperature strain coefficient of 1.7 was created on a curved metallic substrate for the first time. The resistance drift rate at 800 °C for 1 h was 1.1%, which demonstrated the excellent stability and oxidation resistance of the CPTFSG. High-temperature dynamic strain tests up to 769 °C revealed that the sensor had excellent high-temperature strain test performance. Furthermore, the CPTFSG was conformally deposited on an aero-engine turbine blade to perform in situ tensile and compressive strain testing at room temperature. High-temperature strain tests were conducted at 100 and 200 °C for 600 and 580 µÎµ, respectively, demonstrating a high steady-state response consistent with the commercial high-temperature strain transducer. In addition, steady-state strain tests at high temperatures up to 496 °C were tested. The CDIW error modulation strategy provides a highly promising approach for the high-precision fabrication of Pt thick films on complex surfaces and driving in situ sensing of high-temperature parameters on curved components toward practical applications.

Oxidation and Ablation Behavior of Particle-Filled SiCN Precursor Coatings for Thin-Film Sensors.

Polymer-derived ceramic (PDC) thin-film sensors have a very high potential for extreme environments. However, the erosion caused by high-temperature airflow at the hot-end poses a significant challenge to the stability of PDC thin-film sensors. Here, we fabricate a thin-film coating by PDC/TiB2/B composite ceramic material, which can be used to enhance the oxidation resistance and ablation resistance of the sensors. Due to the formation of a dense oxide layer on the surface of the thin-film coating in a high-temperature air environment, it effectively prevents the ingress of oxygen as a pivotal barrier. The coating exhibits an exceptionally thin oxide layer thickness of merely 8 µm, while its oxidation resistance was rigorously assessed under air exposure at 800 °C, proving its enduring protection for a minimum duration of 10 h. Additionally, during ablation testing using a flame gun that can generate temperatures of up to 1000 °C, the linear ablation rate of thin-film coating is merely 1.04 µm/min. Our analysis reveals that the volatilization of B2O3 occurs while new SiO2 is formed on the thin-film coating surface. This phenomenon leads to the absorption of heat, thereby enhancing the ablative resistance performance of the thin-film sensor. The results indicate that the thin-film sensor exhibits exceptional resistance to oxidation and ablation when protected by the coating, which has great potential for aerospace applications.

La(Ca)CrO3-Filled SiCN Precursor Thin Film Temperature Sensor Capable to Measure up to 1100 °C High Temperature.

Thin-film sensors are regarded as advanced technologies for in situ condition monitoring of components operating in harsh environments, such as aerospace engines. Nevertheless, these sensors encounter challenges due to the high-temperature oxidation of materials and intricate manufacturing processes. This paper presents a simple method to fabricate high temperature-resistant oxidized SiCN precursor and La(Ca)CrO3 composite thin film temperature sensors by screen printing and air annealing. The developed sensor demonstrates a broad temperature response ranging from 200 °C to 1100 °C with negative temperature coefficients (NTC). It exhibits exceptional resistance to high-temperature oxidation and maintains performance stability. Notably, the sensor's resistance changes by 3% after exposure to an 1100 °C air environment for 1 h. This oxidation resistance improvement surpasses the currently reported SiCN precursor thin-film sensors. Additionally, the sensor's temperature coefficient of resistance (TCR) can reach up to -7900 ppm/°C at 200 °C. This strategy is expected to be used for other high-temperature thin-film sensors such as strain gauges, heat flux sensors, and thermocouples. There is great potential for applications in high-temperature field monitoring.

Rapid Printing of High-Temperature Polymer-Derived Ceramic Composite Thin-Film Thermistor with Laser Pyrolysis.

Polymer-derived ceramic (PDC)-based high-temperature thin-film sensors (HTTFSs) exhibit promising applications in the condition monitoring of critical components in aerospace. However, fabricating PDC-based HTTFS integrated with high-efficiency, high-temperature anti-oxidation, and customized patterns remains challenging. In this work, we introduce a rapid and flexible selecting laser pyrolysis combined with a direct ink writing process to print double-layer high-temperature antioxidant PDC composite thin-film thermistors under ambient conditions. The sensitive layer (SL) was directly written on an insulating substrate with excellent conductivity by laser-induced graphitization. Then, the antioxidant layer (AOL) was written on the surface of the SL to realize the integrated manufacturing of double-functional layers. Through characterization analysis, it was shown that B2O3 and SiO2 glass phases generated by the PDC composite AOL could effectively prevent oxygen intrusion. Therefore, the fabricated PDC composite thermistors exhibited a negative temperature coefficient in the temperature range from 100 to 1100 °C and high repeatability below 800 °C. Meanwhile, it has excellent high-temperature stability at 800 °C with a resistance change of only 2.4% in 2 h. Furthermore, the high-temperature electrical behavior of the thermistor was analyzed. The temperature dependence of the conductivity for this thermistor has shown an agreement with the Mott's variable range hopping mechanism. Additionally, the thermistor was fabricated on the surface of an aero-engine blade to verify its feasibility below 800 °C, showing the great potential of this work for state sensing on the surface of high-temperature components, especially for customized requirements.

Thin-Film Platinum Resistance Temperature Detector with a SiCN/Yttria-Stabilized Zirconia Protective Layer by Direct Ink Writing for High-Temperature Applications.

In situ temperature monitoring of curved high-temperature components in extreme environments is challenging for a variety of applications in fields such as aero engines and gas turbines. Recently, extrusion-based direct ink writing (DIW) has been utilized to fabricate platinum (Pt) resistance temperature detectors (RTDs). However, the current Pt RTD prepared by DIW technology suffers from a limited temperature range and poor high-temperature stability. Here, DIW technology and yttria-stabilized zirconia (YSZ)-modified precursor ceramic film packaging have been used to build a Pt RTD with high-temperature resistance, small disturbance, and high stability. The results indicate that the protective layer formed by the liquid phase anchors the Pt particles and reduces the agglomeration and volatilization of the Pt sensitive layer at high temperature. Attributed to the SiCN/YSZ protective layer, the temperature resistance curve of the Pt RTD in the range of 50-800 °C has little deviation from the fitting curve, and the fitting correlation coefficient is above 0.9999. Interestingly, the Pt RTD also has high repeatability and stability. The high temperature resistance drift rate is only 0.05%/h after 100 h of long-term testing at 800 °C and can withstand butane flame up to ∼1300 °C without damage. Moreover, the Pt RTD can be conformally deposited on the outer ring of aerospace bearings by DIW technology and then realize on-site, nondestructive, and real-time monitoring of bearing temperature. The fabricated Pt RTD shows great potential for high-temperature applications, and the novel technology proposed provides a feasible pathway for temperature monitoring of aeroengine internal curved hot-end components.

All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass-Ceramic Protective Layer for High-Temperature Applications.

A high-temperature thin/thick-film strain gauge (TFSG) shows development prospects for in situ strain monitoring of hot-end components due to their small perturbations, no damage, and fast response. Direct ink writing (DIW) 3D printing is an emerging and facile approach for the rapid fabrication of TFSG. However, TFSGs prepared based on 3D printing with both high thermal stability and low temperature coefficient of resistance (TCR) over a wide temperature range remain a great challenge. Here, we report a AgPd TFSG with a glass-ceramic protective layer based on DIW. By encapsulating the AgPd sensitive layer and regulating the Pd content, the AgPd TFSG demonstrated a low TCR (191.6 ppm/°C) from 50 to 800 °C and ultrahigh stability (with a resistance drift rate of 0.14%/h at 800 °C). Meanwhile, the achieved specifications for strain detection included a strain sensing range of ±500 µÎµ, fast response time of 153 ms, gauge factor of 0.75 at 800 °C, and high durability of >8000 cyclic loading tests. The AgPd TFSG effectively monitors strain in superalloys and can be directly deposited onto cylindrical surfaces, demonstrating the scalability of the presented approach. This work provides a strategy to develop TFSGs for in situ sensing of complex curved surfaces in harsh environments.

In Situ Laser Fabrication of Polymer-Derived Ceramic Composite Thin-Film Sensors for Harsh Environments.

Polymer-derived ceramic (PDC) is considered an excellent sensing material for harsh environments such as aero-engines and nuclear reactors. However, there are many inherent limitations not only in pure PDC but also in its common fabrication method by furnace thermolysis. Therefore, this study proposes a novel method of rapid in situ fabrication of PDC composite thin-film sensors by laser pyrolysis. Using this method with different fillers, a sensitive PDC composite film layer with high-quality graphite can be obtained quickly, which is more flexible and efficient compared to the traditional furnace thermolysis. Furthermore, this study analyzes the reaction differences between laser pyrolysis and furnace thermolysis. The laser pyrolysis method principally produces ß-SiC and enhances the graphitization of amorphous carbon, while the degree of graphitization by furnace thermolysis is low. In addition, it is capable of rapidly preparing an insulating PDC composite film, which still has a resistance of 5 MΩ at 600 °C. As a proof of this method, the PDC composite thin-film strain sensors are fabricated in situ on nickel alloys and aluminum oxide substrates, respectively. The sensor fabricated on the nickel alloy with a high gauge factor of over 100 can be used in high-temperature environments below 350 °C without the protection of an oxidation-resistant coating. In this way, the approach pioneers the in situ laser fabrication of functional PDC films for sensors, and it has great potential for the in situ sensing of complex curved surfaces in harsh environments.

Nanofiber self-consistent additive manufacturing process for 3D microfluidics.

3D microfluidic devices have emerged as powerful platforms for analytical chemistry, biomedical sensors, and microscale fluid manipulation. 3D printing technology, owing to its structural fabrication flexibility, has drawn extensive attention in the field of 3D microfluidics fabrication. However, the collapse of suspended structures and residues of sacrificial materials greatly restrict the application of this technology, especially for extremely narrow channel fabrication. In this paper, a 3D printing strategy named nanofiber self-consistent additive manufacturing (NSCAM) is proposed for integrated 3D microfluidic chip fabrication with porous nanofibers as supporting structures, which avoids the sacrificial layer release process. In the NSCAM process, electrospinning and electrohydrodynamic jet (E-jet) writing are alternately employed. The porous polyimide nanofiber mats formed by electrospinning are ingeniously applied as both supporting structures for the suspended layer and percolating media for liquid flow, while the polydimethylsiloxane E-jet writing ink printed on the nanofiber mats (named construction fluid in this paper) controllably permeates through the porous mats. After curing, the resultant construction fluid-nanofiber composites are formed as 3D channel walls. As a proof of concept, a microfluidic pressure-gain valve, which contains typical features of narrow channels and movable membranes, was fabricated, and the printed valve was totally closed under a control pressure of 45 kPa with a fast dynamic response of 52.6 ms, indicating the feasibility of NSCAM. Therefore, we believe NSCAM is a promising technique for manufacturing microdevices that include movable membrane cavities, pillar cavities, and porous scaffolds, showing broad applications in 3D microfluidics, soft robot drivers or sensors, and organ-on-a-chip systems.

Multistage Digital-to-Analogue Chip Based on a Weighted Flow Resistance Network for Soft Actuators.

A control chip with a multistage flow-rate regulation function based on the correlation between the flow resistance and flow rate has been developed in this article. Compared with the traditional proportional solenoid valve, this kind of flow valve based on microfluidic technology has the characteristics of being light-weight and having no electric drive. It solves such technical problems as how the current digital microfluidic chip can only adjust the flow switch, and the adjustment of the flow rate is difficult. To linearize the output signal, we propose a design method of weighted resistance. The output flow is controlled by a 4-bit binary pressure signal. According to the binary value of the 4-bit pressure signal at the input, the output can achieve 16-stage flow adjustment. Furthermore, we integrate the three-dimensional flow resistance network, multilayer structure microvalve, and parallel fluid network into a single chip by using 3D printing to obtain a modular flow control unit. This structure enables the microflow control signal to be converted from a digital signal to an analogue signal (DA conversion), and is suitable for microflow driving components, such as in microfluidic chip sampling systems and proportional mixing systems. In the future, we expect this device to even be used in the automatic control system of a miniature pneumatic soft actuator.

A microfluidically controlled concave-convex membrane lens using an addressing operation system.

Electrical control toolkits for microlens arrays are available to some extent, but for applications in environments with strong electromagnetic fields, radiation, or deep water, non-electrical actuation and control strategies are more appropriate. An integrated digital microfluidic zoom actuating unit with a logic addressing unit for a built-in membrane lens array, e.g., a flexible bionic compound eye, is developed and studied in this article. A concave-convex membrane fluidic microvalve, which is the component element of the logic gate, actuator, and microlens, is proposed to replace the traditional solenoid valve. The functions of pressure regulation and decoding can be obtained by incorporating microvalves into fluidic networks according to equivalent circuit designs. The zoom actuating unit contains a pressure regulator to adjust the focal length of lenses with three levels, and the logic addressing unit contains a decoder to choose a typical lens from a hexagonal lens array. The microfluidic chip control system is connected flexibly to the actuating part, a membrane lens array. It is shown from a simulation and experimental demonstration that the designed and fabricated system, which is composed of a whole microfluidic zoom unit, addressing technology, and a microlens array, works well. Because these components are constructed in the same fabrication process and operate with the same work media and driving source, the system can be made highly compatible and lightweight for applications such as human-machine interfaces and soft robots.

Effect of Enhanced Squeezing Needle Structure on the Jetting Performance of a Piezostack-Driven Dispenser.

Advanced dispensing technology is urgently needed to improve the jetting performance of fluid to meet the requirements of electronic product integration and miniaturization. In this work, an on-off valve piezostack-driven dispenser was used as a study object to investigate the effect of needle structure on jetting performance. Based on fluid dynamics, we investigated nozzle cavity pressure and jet velocity during the dispensing process using theoretical simulation for needles with and without a side cap. The results showed that the needle with a side cap had larger jet velocity and was capable of generating 8.27 MPa of pressure in the nozzle cavity, which was 2.39 times larger than the needle without a side cap. Further research on the influence of the nozzle and needle structural parameters showed that a nozzle conic angle of 85°-105°, needle conic angle of 10°-35°, and side clearance of 0.1-0.3 mm produced a dispenser with a large jet velocity and stable performance, capable of dispensing microscale droplets. Finally, a smaller droplet diameter of 0.42 mm was achieved in experiments using a glycerol/ethanol mixture, with a variation range of ± 4.61%.