manufacturing-three-dimensionally-microstructured-nanocomposites

Manufacturing of Three-dimensionally Microstructured Nanocomposites through Microfluidic Infiltration

Microstructured composite beams reinforced with complex three-dimensionally (3D) patterned nanocomposite microfilaments are fabricated via nanocomposite ...

Chaotisches Mischen im dreidimensionalen mikrovaskul&#xE4;ren Netzwerken durch direkte Schreib-Anordnung hergestellt.

The creation of geometrically complex fluidic devices is a subject of broad fundamental and technological interest. Here, we demonstrate the fabrication of three-dimensional (3D) microvascular networks through direct-write assembly of a fugitive organic ink. This approach yields a pervasive network of smooth cylindrical channels (approximately 10-300 microm) with defined connectivity. Square-spiral towers, isolated within this vascular network, promote fluid mixing through chaotic advection. These vertical towers give rise to dramatic improvements in mixing relative to simple straight (1D) and square-wave (2D) channels while significantly reducing the device planar footprint. We envisage that 3D microvascular networks will provide an enabling platform for a wide array of fluidic-based applications.

Chaotic mixing in three-dimensional microvascular networks fabricated by direct-write assembly.

A CO2 laser (lambda = 10.6 microm) was used to heat a solution of water and alcohol saturated by Zn(AcAc)2 on a fused quartz substrate in open air. After only a few seconds of irradiation, various zinc oxide (ZnO) nanostructures including nanorods and nanowires are formed near the center of the irradiated zone, surrounded by a porous thin film of ZnO nanoparticles. The type of structures produced and their localization on the substrate can be varied by selecting adequate irradiation time and laser power ranges. The deposits have been analyzed using SEM, TEM, EDS, XRD, and Raman spectroscopy, revealing that the nanorods (aspect ratio ~6) and nanowires (aspect ratio ~94) are single-crystalline structures which grow along the c axis of wurtzite ZnO. The nanoparticles are also single-crystalline and have an average diameter of 16 nm. A qualitative model for nanostructure growth is proposed, based on previous studies of aqueous solution and hydrothermal processing.

Fast synthesis of ZnO nanostructures by laser-induced decomposition of zinc acetylacetonate.

Biosensors: filling the gap.

Ultraviolet-assisted direct-write fabrication of carbon nanotube/polymer nanocomposite microcoils.

A large number of polyester nanocomposite batches featuring different kinds of nanoclay surface modifiers and up to 6 wt % nanoclay were manufactured using a solvent-based technique. Montmorillonite platelets modified with ammonium ions of different chemical architectures were examined to study the effect of ammonium ions on the extent of surface reactions with long-chain fatty acids. The ammonium montmorillonite was first dispersed and suspended in acetone. This suspension was further esterificated with dotriacontanoic (lacceroic) acid to form high density brushes on the clay surface. This led to achieving higher basal plane spacing of the montmorillonite platelets due to the reduction of electrostatic interactions holding them. The outcome of the surface esterification was analyzed by Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD). The esterificated ammonium-modified clays were then mixed by five different mixing strategies based on the use of a three-roll mill mixer (TRM) and/or ultrasonication (US) to obtain the desired polyester-nanoclay dispersion, intercalation, and exfoliation. The dispersion states of the modified nanoclay in polymer were characterized from XRD, scanning electron microscopy (SEM), and low and high magnification transmission electron microscopy (TEM). Mechanical, thermal, and barrier properties of the resulting composites were experimentally characterized. The Mori-Tanaka method along with an orientation distribution function was used to verify the experimental effective stiffness of the polyester nanocomposite systems. The aspect ratio of nanoclays and their level of intercalation and/or exfoliation after mixing were also confirmed by the comparison of the experimental diffusivity results with those of Fick's diffusion model. Systems having 4 and 6 wt % esterificated ammonium nanoclay and prepared according to a combined TRM/US mixing procedure showed optimal performance with balanced properties and processing ease, thereby showing potential for use in the automotive, transportation, and packaging industries.

Preparation of highly exfoliated polyester-clay nanocomposites: process-property correlations.

This paper deals with the design and microfabrication of two three-dimensional (3D) freestanding patterned strain sensors made of single-walled carbon nanotube (SWCNT) nanocomposites with the ultraviolet-assisted direct-write (UV-DW) technique. The first sensor consisted of three nanocomposite microfibers suspended between two rectangular epoxy pads. The flexibility of the UV-DW technique enables the sensor and its housing to be manufactured in one monolithic structure. The second sensor was composed of a nanocomposite network consisting of four parallel microsprings, which demonstrates the high capability of the technique when compared to conventional photolithographic technologies. The performances of the sensors were assessed under tension and compression, respectively. The sensors' sensitivities were evaluated by correlating their measured resistivities to the applied displacements/strains. Electrical conductivity measurements revealed that the manufactured sensors are highly sensitive to small mechanical disturbances, especially for lower nanotube loadings when compared to traditional metallic or nanocomposite films. The present manufacturing method offers a new perspective for manufacturing highly sensitive 3D freestanding microstructured sensors.

Direct-write fabrication of freestanding nanocomposite strain sensors.

The solvent-cast direct-write fabrication of microstructures is shown using a thermoplastic polymer solution ink. The method employs the robotically controlled microextrusion of a filament combined with a rapid solvent evaporation. Upon drying, the increased rigidity of the extruded filament enables the creation of complex freeform 3D shapes.

Solvent-cast three-dimensional printing of multifunctional microsystems.

Solvent-cast printing is a highly versatile microfabrication technique that can be used to construct various geometries such as filaments, towers, scaffolds, and freeform circular spirals by the robotic deposition of a polymer solution ink onto a moving stage. In this work, we have performed a comprehensive characterization of the solvent-cast printing process using polylactide (PLA) solutions by analyzing the flow behavior of the solutions, the solvent evaporation kinetics, and the effect of process-related parameters on the crystallization of the extruded filaments. Rotational rheometry at low to moderate shear rates showed a nearly Newtonian behavior of the PLA solutions, while capillary flow analysis based on process-related data indicated shear thinning at high shear rates. Solvent vaporization tests suggested that the internal diffusion of the solvent through the filaments controlled the solvent removal of the extrudates. Different kinds of three-dimensional (3D) structures including a layer-by-layer tower, nine-layer scaffold, and freeform spiral were fabricated, and a processing map was given to show the proper ranges of process-related parameters (i.e., polymer content, applied pressure, nozzle diameter, and robot velocity) for the different geometries. The results of differential scanning calorimetry revealed that slow solvent evaporation could increase the ability of PLA to complete its crystallization process during the filament drying stage. The method developed here offers a new perspective for manufacturing complex structures from polymer solutions and provides guidelines to optimize the various parameters for 3D geometry fabrication.

Article	Year
Chaotic mixing in three-dimensional microvascular networks fabricated by direct-write assembly. Nature materials\| PubMed ID: 12690401	2003
Fast synthesis of ZnO nanostructures by laser-induced decomposition of zinc acetylacetonate. Inorganic chemistry\| PubMed ID: 18027927	2007
Biosensors: filling the gap. Nature nanotechnology\| PubMed ID: 18654319	2007
Ultraviolet-assisted direct-write fabrication of carbon nanotube/polymer nanocomposite microcoils. Advanced materials (Deerfield Beach, Fla.)\| PubMed ID: 20217755	2010
Preparation of highly exfoliated polyester-clay nanocomposites: process-property correlations. Langmuir : the ACS journal of surfaces and colloids\| PubMed ID: 22087630	2012
Direct-write fabrication of freestanding nanocomposite strain sensors. Nanotechnology\| PubMed ID: 22293315	2012
Solvent-cast three-dimensional printing of multifunctional microsystems. Small (Weinheim an der Bergstrasse, Germany)\| PubMed ID: 23824963	2013
Properties of polylactide inks for solvent-cast printing of three-dimensional freeform microstructures. Langmuir : the ACS journal of surfaces and colloids\| PubMed ID: 24410099	2014

Daniel Therriault

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