The toughness of mechanical metamaterials.

Rapid progress in additive manufacturing methods has created a new class of ultralight mechanical metamaterials with extreme functional properties. Their application is ultimately limited by their tolerance to damage and defects, but an understanding of this sensitivity has remained elusive. Using metamaterial specimens consisting of millions of unit cells, we show that not only is the stress intensity factor, as used in conventional elastic fracture mechanics, insufficient to characterize fracture, but also that conventional fracture testing protocols are inadequate. Via a combination of numerical and asymptotic analysis, we extend the ideas of elastic fracture mechanics to truss-based metamaterials and develop a general test and design protocol. This framework can form the basis for fracture characterization in other discrete elastic-brittle solids where the notion of fracture toughness is known to break down.

Three-dimensional printing of piezoelectric materials with designed anisotropy and directional response.

Piezoelectric coefficients are constrained by the intrinsic crystal structure of the constituent material. Here we describe design and manufacturing routes to previously inaccessible classes of piezoelectric materials that have arbitrary piezoelectric coefficient tensors. Our scheme is based on the manipulation of electric displacement maps from families of structural cell patterns. We implement our designs by additively manufacturing free-form, perovskite-based piezoelectric nanocomposites with complex three-dimensional architectures. The resulting voltage response of the activated piezoelectric metamaterials at a given mode can be selectively suppressed, reversed or enhanced with applied stress. Additionally, these electromechanical metamaterials achieve high specific piezoelectric constants and tailorable flexibility using only a fraction of their parent materials. This strategy may be applied to create the next generation of intelligent infrastructure, able to perform a variety of structural and functional tasks, including simultaneous impact absorption and monitoring, three-dimensional pressure mapping and directionality detection.

Multiscale metallic metamaterials.

Materials with three-dimensional micro- and nanoarchitectures exhibit many beneficial mechanical, energy conversion and optical properties. However, these three-dimensional microarchitectures are significantly limited by their scalability. Efforts have only been successful only in demonstrating overall structure sizes of hundreds of micrometres, or contain size-scale gaps of several orders of magnitude. This results in degraded mechanical properties at the macroscale. Here we demonstrate hierarchical metamaterials with disparate three-dimensional features spanning seven orders of magnitude, from nanometres to centimetres. At the macroscale they achieve high tensile elasticity (>20%) not found in their brittle-like metallic constituents, and a near-constant specific strength. Creation of these materials is enabled by a high-resolution, large-area additive manufacturing technique with scalability not achievable by two-photon polymerization or traditional stereolithography. With overall part sizes approaching tens of centimetres, these unique nanostructured metamaterials might find use in a broad array of applications.

3D Printing and processing of miniaturized transducers with near-pristine piezoelectric ceramics for localized cavitation.

The performance of ultrasonic transducers is largely determined by the piezoelectric properties and geometries of their active elements. Due to the brittle nature of piezoceramics, existing processing tools for piezoelectric elements only achieve simple geometries, including flat disks, cylinders, cubes and rings. While advances in additive manufacturing give rise to free-form fabrication of piezoceramics, the resultant transducers suffer from high porosity, weak piezoelectric responses, and limited geometrical flexibility. We introduce optimized piezoceramic printing and processing strategies to produce highly responsive piezoelectric microtransducers that operate at ultrasonic frequencies. The 3D printed dense piezoelectric elements achieve high piezoelectric coefficients and complex architectures. The resulting piezoelectric charge constant, d33, and coupling factor, kt, of the 3D printed piezoceramic reach 583 pC/N and 0.57, approaching the properties of pristine ceramics. The integrated printing of transducer packaging materials and 3D printed piezoceramics with microarchitectures create opportunities for miniaturized piezoelectric ultrasound transducers capable of acoustic focusing and localized cavitation within millimeter-sized channels, leading to miniaturized ultrasonic devices that enable a wide range of biomedical applications.

Design and printing of proprioceptive three-dimensional architected robotic metamaterials.

Advances in additive manufacturing techniques have enabled the creation of stimuli-responsive materials with designed three-dimensional (3D) architectures. Unlike biological systems in which functions such as sensing, actuation, and control are closely integrated, few architected materials have comparable system complexity. We report a design and manufacturing route to create a class of robotic metamaterials capable of motion with multiple degrees of freedom, amplification of strain in a prescribed direction in response to an electric field (and vice versa), and thus, programmed motions with self-sensing and feedback control. These robotic metamaterials consist of networks of piezoelectric, conductive, and structural elements interwoven into a designed 3D lattice. The resulting architected materials function as proprioceptive microrobots that actively sense and move.

A general method to synthesize and sinter bulk ceramics in seconds.

Ceramics are an important class of materials with widespread applications because of their high thermal, mechanical, and chemical stability. Computational predictions based on first principles methods can be a valuable tool in accelerating materials discovery to develop improved ceramics. It is essential to experimentally confirm the material properties of such predictions. However, materials screening rates are limited by the long processing times and the poor compositional control from volatile element loss in conventional ceramic sintering techniques. To overcome these limitations, we developed an ultrafast high-temperature sintering (UHS) process for the fabrication of ceramic materials by radiative heating under an inert atmosphere. We provide several examples of the UHS process to demonstrate its potential utility and applications, including advancements in solid-state electrolytes, multicomponent structures, and high-throughput materials screening.