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.
AbstractSection
Highlights
Facile fabrication of high-transconductance (>10 mS) and highly elastic all-polymer organic electrochemical transistors was presented using gelatin-based electrolyte supporting printed PEDOT:PSS/LiTFSI microstructures.
PEDOT:PSS/LiTFSI wrinkled microelectrodes and imprinted 3D-microstructured channel/electrolyte interface allowed biaxial stretchability of 100% strain and performance preservation after 1000 cycles of 80% strain.
The glycerol-soaked elastic gelatin electrolyte also permitted long-term environmental stability for months and enabled readily recyclable device, paving the way to wide applications spanning from artificial synapses to wearable sensing.
Elastomer-based resistive super-thin film strain sensors show great application potentials in electronic skins, human–machine interaction systems, wearable devices for healthcare, and machine learning algorithms. However, it is challenging to accurately monitor the deformation of human body joints and organs with curved surfaces (e.g., knees, throats, finger joints) by only taking advantage of material thickness and elasticity of conventional 2D film strain sensors. Herein, a simple strategy is developed to fabricate conformal elastomeric thin film sensors with periodic 3D microstructure inspired by the ridges and valleys of human skin for accurate signal acquisition. Specifically, an 8-micrometer-thick elastic film strain sensor with 3D microstructure is fabricated via thermoforming followed by in situ chemical growth of silver nanoparticles. The 3D film strain sensors exhibit excellent signal linearity (R 2 = 0.99) and relatively high sensitivity (gauge factor = 14) over a relatively wide strain range (≈43%), with an ultra-low strain detection limit of 0.025%, enabling potential applications in human healthcare monitoring and air leakage detection. Thus, this study unveils a simple methodology to process microstructure-enabled conformable 3D film strain sensors, which show good conformability and multiple mechanical sensing functions for advancing the development of next-generation flexible strain sensors.
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