Ambient Pressure Drying of Freeze-Cast Ceramics from Aqueous Suspension.

Freeze-casting has been wildly exploited to construct porous ceramics but usually requires costly and demanding freeze-drying (high vacuum, size limit, and supercooled chamber), which can be avoided by the ambient pressure drying (APD) technique. However, applying APD to freeze-cast ceramic based on an aqueous suspension is still challenging due to inert surface chemistry. Herein, a modified APD strategy is developed to improve the drying process of freeze-cast ceramics by exploiting the simultaneous ice etching, ionic cross-linking, and solvent exchange under mild conditions (-10-0 °C, ambient pressure). This versatile strategy is applicable to various ceramic species, metal ions, and freezing techniques. The incorporated metal ions not only enhance liquid-phase sintering, producing ceramics with higher density and mechanical properties than freeze-cast counterparts, but also render customizable coloration and antibacterial property. The cost-/time-efficient APD is promising for mass production and even successive production of large-size freeze-cast ceramics that exceed the size of commercial freeze-dryers.

Biomimetic Gradient Bouligand Structure Enhances Impact Resistance of Ceramic-Polymer Composites.

Biological materials relied on multiple synergistic structural design elements typically exhibit excellent comprehensive mechanical properties. Hierarchical incorporation of different biostructural elements into a single artificial material is a promising approach to enhance mechanical properties, but remains challenging. Herein, a biomimetic structural design strategy is proposed by coupling gradient structure with twisted plywood Bouligand structure, attempting to improve the impact resistance of ceramic-polymer composites. Via robocasting and sintering, kaolin ceramic filaments reinforced by coaxially aligned alumina nanoplatelets are arranged into Bouligand structure with a gradual transition in filament spacing along the thickness direction. After the following polymer infiltration, biomimetic ceramic-polymer composites with a gradient Bouligand (GB) structure are eventually fabricated. Experimental investigations reveal that the incorporation of gradient structure into Bouligand structure improves both the peak force and total energy absorption of the obtained ceramic-polymer composites. Computational modeling further suggests the substantial improvement in impact resistance by adopting GB structure, and clarifies the underlying deformation behavior of the biomimetic GB structured composites under impact. This biomimetic design strategy may provide valuable insights for developing lightweight and impact-resistant structural materials in the future.

Scalable Manufacturing of Mechanical Robust Bioinspired Ceramic-Resin Composites with Locally Tunable Heterogeneous Structures.

Lightweight structural materials with a unique combination of high stiffness, strength, toughness, and hardness, are highly desired yet challenging to be artificially fabricated. Biological structural materials, on the other hand, ingeniously integrate multiple mutually exclusive mechanical properties together relying on their hierarchically heterogeneous structures bonded with gradient interfaces. Here, a scalable bottom-up approach combining continuous nanofiber-assisted evaporation-induced self-assembly with laminating, pressure-less sintering and resin infiltration is reported to fabricate bioinspired heterogeneous ceramic-resin composites with locally tunable microstructure to fulfill specific properties. A gradient interlayer is introduced to provide a gradual transition between adjacent heterogeneous layers, effectively alleviating their property mismatch. The optimized heterogeneous nacre-like composite, as a demonstration, exhibits an attractive combination of low density (≈2.8 g cm-3 ), high strength (≈292 MPa), toughness (≈6.4 MPa m1/2 ), surface hardness (≈1144 kgf mm-2 ) and impact-resistance, surpassing the overall performance of engineering alumina. This material-independent approach paves the way for designing advanced bioinspired heterogeneous materials for diverse structural and functional applications.

Controlled Desiccation of Preprinted Hydrogel Scaffolds Toward Complex 3D Microarchitectures.

Additive manufacturing (AM) is the key to creating a wide variety of 3D structures with unique and programmable functionalities. Direct ink writing is one of the widely used AM technologies with numerous printable materials. However, the extrude-based method is limited by low fabrication resolution, which is confined to printing macrostructures. Herein, a new AM strategy is reported, using a low-cost extrusion 3D printer, to create 3D microarchitectures at the macroscopic level through controlled desiccation of preprinted hydrogel scaffolds followed by infilling objective components. A printable hydrogel with a high-water content ensures maximum shrinkage (≈99.5% in volume) of the printed scaffolds to achieve high resolution. Stable covalent cross-linking and a suitable drying rate enable uniform shrinkage of the scaffolds to retain their original architectures. Particularly, this method can be adapted to produce liquid-metal-based 3D circuits and nanocomposite-based microrobots, indicating its capability to fabricate functional and complex 3D architectures with micron-level resolution from different material systems.

A Highly Compressible and Stretchable Carbon Spring for Smart Vibration and Magnetism Sensors.

Porous carbon materials demonstrate extensive applications for their attractive characteristics. Mechanical flexibility is an essential property guaranteeing their durability. After decades of research efforts, compressive brittleness of porous carbon materials is well resolved. However, reversible stretchability remains challenging to achieve due to the intrinsically weak connections and fragile joints of the porous carbon networks. Herein, it is presented that a porous all-carbon material achieving both elastic compressibility and stretchability at large strain from -80% to 80% can be obtained when a unique long-range lamellar multi-arch microstructure is introduced. Impressively, the porous all-carbon material can maintain reliable structural robustness and durability under loading condition of cyclic compressing-stretching process, similar to a real metallic spring. The unique performance renders it as a promising platform for making smart vibration and magnetism sensors, even capable of operating at extreme temperatures. Furthermore, this study provides valuable insights for creating highly stretchable and compressible porous materials from other neat inorganic components for diverse applications in future.

Bioinspired hierarchical helical nanocomposite macrofibers based on bacterial cellulose nanofibers.

Bio-sourced nanocellulosic materials are promising candidates for spinning high-performance sustainable macrofibers for advanced applications. Various strategies have been pursued to gain nanocellulose-based macrofibers with improved strength. However, nearly all of them have been achieved at the expense of their elongation and toughness. Inspired by the widely existed hierarchical helical and nanocomposite structural features in biosynthesized fibers exhibiting exceptional combinations of strength and toughness, we report a design strategy to make nanocellulose-based macrofibers with similar characteristics. By combining a facile wet-spinning process with a subsequent multiple wet-twisting procedure, we successfully obtain biomimetic hierarchical helical nanocomposite macrofibers based on bacterial cellulose nanofibers, realizing impressive improvement in their tensile strength, elongation and toughness simultaneously. The achievement certifies the validity of the bioinspired hierarchical helical and nanocomposite structural design proposed here. This bioinspired design strategy provides a potential platform for further optimizing or creating many more strong and tough nanocomposite fiber materials for diverse applications.