Fabrication of tough epoxy with shape memory effects by UV-assisted direct-ink write printing.

3D printing of epoxy-based shape memory polymers with high mechanical strength, excellent thermal stability and chemical resistance is highly desirable for practical applications. However, thermally cured epoxy in general is difficult to print directly. There have been limited numbers of successes in printing epoxy but they suffer from relatively poor mechanical properties. Here, we present an ultraviolet (UV)-assisted 3D printing of thermally cured epoxy composites with high tensile toughness via a two-stage curing approach. The ink containing UV curable resin and epoxy oligomer is used for UV-assisted direct-ink write (DIW)-based 3D printing followed by thermal curing of the part containing the epoxy oligomer. The UV curable resin forms a network by photo polymerization after the 1st stage of UV curing, which can maintain the printed architecture at an elevated temperature. The 2nd stage thermal curing of the epoxy oligomer yields an interpenetrating polymer network (IPN) composite with highly enhanced mechanical properties. It is found that the printed IPN epoxy composites enabled by the two-stage curing show isotropic mechanical properties and high tensile toughness. We demonstrated that the 3D-printed high-toughness epoxy composites show good shape memory properties. This UV-assisted DIW 3D printing via a two-stage curing method can broaden the application of 3D printing to fabricate thermoset materials with enhanced tensile toughness and tunable properties for high-performance and functional applications.

High-Speed 3D Printing of High-Performance Thermosetting Polymers via Two-Stage Curing.

Design and direct fabrication of high-performance thermosets and composites via 3D printing are highly desirable in engineering applications. Most 3D printed thermosetting polymers to date suffer from poor mechanical properties and low printing speed. Here, a novel ink for high-speed 3D printing of high-performance epoxy thermosets via a two-stage curing approach is presented. The ink containing photocurable resin and thermally curable epoxy resin is used for the digital light processing (DLP) 3D printing. After printing, the part is thermally cured at elevated temperature to yield an interpenetrating polymer network epoxy composite, whose mechanical properties are comparable to engineering epoxy. The printing speed is accelerated by the continuous liquid interface production assisted DLP 3D printing method, achieving a printing speed as high as 216 mm h-1 . It is also demonstrated that 3D printing structural electronics can be achieved by combining the 3D printed epoxy composites with infilled silver ink in the hollow channels. The new 3D printing method via two-stage curing combines the attributes of outstanding printing speed, high resolution, low volume shrinkage, and excellent mechanical properties, and provides a new avenue to fabricate 3D thermosetting composites with excellent mechanical properties and high efficiency toward high-performance and functional applications.

Additively Manufactured Dual-Faced Structured Fabric for Shape-Adaptive Protection.

Fabric-based materials have demonstrated promise for high-performance wearable applications but are currently restricted by their deficient mechanical properties. Here, this work leverages the design freedom offered by additive manufacturing and a novel interlocking pattern to for the first time fabricate a dual-faced chain mail structure consisting of 3D re-entrant unit cells. The flexible structured fabric demonstrates high specific energy absorption and specific strength of up to 1530 J kg-1 and 5900 Nm kg-1 , respectively, together with an excellent recovery ratio of ≈80%, thereby overcoming the strength-recoverability trade-off. The designed dual-faced structured fabric compares favorably against a wide range of materials proposed for wearable applications, attributed to the synergetic strengthening of the energy-absorbing re-entrant unit cells and their unique topological interlocking. This work advocates the combined design of energy-absorbing unit cells and their interlocking to extend the application prospects of fabric-based materials to shape-adaptive protection.

Biomass-derived carbon-based and silica-based materials for catalytic and adsorptive applications- An update since 2010.

Biomass, which defined as plant- or animal-based materials, is intriguing tremendous scientific attentions due to its renewable attribute in serving energy security. Amongst, the plant-based biomasses, particularly those that co-generated in the agriculture activities, are commonly regarded as fuel for burning, which overlooked their hidden potentials for high-end applications. Organically, the plant-based biomass constitutes of lignocellulose components, which can be served as promising precursors for functionalized carbon materials. Meanwhile, its inorganic counterpart made up of various minerals, with Si being the most concerned one. With the advancement of biomass technologies and material synthesis in recent years, numerous attempts were endeavoured to obtain valorised products from biomass. Particularly, syntheses of catalytic and adsorptive materials are actively researched in the field of biomass reutilization. Herein, our work systematically summarized the advancements of biomass-materials for these applications in recent 10 years (2010-2020), with a special focus on the carbon-based and Si-based catalytic/adsorptive materials. Significantly, the deriving steps, inclusive of both pre-treatment and post-treatment of such materials, are incorporated in the discussion, alongside with their significances revealed too. The performance of the as-obtained materials in the respective application is systematically correlated to their physicochemical properties, hence providing valuable insights to the readers. Challenges and promising directions to be explored are raised too at the end of the review, aiming to advocate better-usage of biomass while offering great opportunities to sustain catalysis and adsorption in the industrial scale.

Elimination of energy-consuming mechanical stirring: Development of auto-suspending ZnO-based photocatalyst for organic wastewater treatment.

Powdered-photocatalysis of organic wastewater is widely investigated, unfortunately not industrially implemented due to its high energy requirement. Interestingly, such issue may be alleviated via the elimination of mechanical stirring required. Core-shell ZnO-based photocatalysts were developed herein, subsequently demonstrated efficient photocatalytic activities in the absence of mechanical stirring. Results show that the developed SiO2-cored ZnO photocatalyst are highly crystalline, while significantly smaller than coreless, pure ZnO due to the multi-point crystallization prompted. Additionally, it is also inherited with considerable buoyancy ability from SiO2-core in the absence of mechanical stirring, concurrently rendered with UV-active properties due to its ZnO-shell. Experimentally, 55% of particles of ZnO_0.0025 (0.0025 mol of ZnO-deposition) were found stably suspended for 60 min in liquid substrate, as opposed to the instant-settling of pure ZnO particles. In term of photocatalytic activity, ZnO_0.01 manifested the best methylene blue (MB) degradation with 150 mL/min of O2-bubbling. 67.63% of MB was degraded with photocatalyst loading of 0.2 g/L after 120 min UV-irradiation, simultaneously recorded the highest pseudo-first order reaction constant of 9.636 × 10-3 min-1. As summary, the auto-suspending photocatalysis conceptualized in current study offers a high possibility in reducing energy requirement for photo-treatment of wastewater, hence advocating its industrialization potential in near future.

In Situ Observation on Rate-Dependent Strain Localization of Thermo-Induced Shape Memory Polyurethane.

In situ monotonic tensile experiments of thermo-induced shape memory polyurethane (SMPU) at different loading rates were carried out by the digital image correlation (DIC) method and infrared camera FLIR®-A655sc in natural convection (NC) and forced convection (FC) conditions, respectively. The multiform strain localization of SMPU was observed by the DIC method, and the influence of thermo-mechanical coupling on the strain localization was analyzed by using the FLIR to measure the temperature field caused by the internal heat generation. The experimental results show that the strain localization mode strongly depends on the strain rate and convection condition, and the strain localization mode can be transformed by changing the convection condition from NC to FC. The competition mechanism between the strain hardening induced by the increasing loading rate and strain softening induced by the internal heat generation is indicated, the transition modes of strain localization are clarified, and the influences of thermo-mechanical coupling on shape memory effect are discussed.

Grayscale digital light processing 3D printing for highly functionally graded materials.

Three-dimensional (3D) printing or additive manufacturing, as a revolutionary technology for future advanced manufacturing, usually prints parts with poor control of complex gradients for functional applications. We present a single-vat grayscale digital light processing (g-DLP) 3D printing method using grayscale light patterns and a two-stage curing ink to obtain functionally graded materials with the mechanical gradient up to three orders of magnitude and high resolution. To demonstrate the g-DLP, we show the direct fabrication of complex 2D/3D lattices with controlled buckling and deformation sequence, negative Poisson's ratio metamaterial, presurgical models with stiffness variations, composites for 4D printing, and anti-counterfeiting 3D printing.

3D Printing of Highly Stretchable, Shape-Memory, and Self-Healing Elastomer toward Novel 4D Printing.

The three-dimensional (3D) printing of flexible and stretchable materials with smart functions such as shape memory (SM) and self-healing (SH) is highly desirable for the development of future 4D printing technology for myriad applications, such as soft actuators, deployable smart medical devices, and flexible electronics. Here, we report a novel ink that can be used for the 3D printing of highly stretchable, SM, and SH elastomer via UV-light-assisted direct-ink-write printing. An ink containing urethane diacrylate and a linear semicrystalline polymer is developed for the 3D printing of a semi-interpenetrating polymer network elastomer that can be stretched by up to 600%. The 3D-printed complex structures show interesting functional properties, such as high strain SM and SM -assisted SH capability. We demonstrate that such a 3D-printed SM elastomer has the potential application for biomedical devices, such as vascular repair devices. This research paves a new way for the further development of novel 4D printing, soft robotics, and biomedical devices.