A prototype for 3D electrohydrodynamic printing

Electrohydrodynamic direct writing is a flexible cost effective alternative technique that is capable of producing a very fine jet of liquid in the presence of an external electric field. This jet can then be used to pattern surfaces in an ordered and controlled fashion and offers a robust route to low cost large area micro and nano-manufacturing. Unlike other types of direct writing techniques, the liquid in electrohydrodynamic printing is subjected to both pushing and pulling forces. The pushing force is brought about by the constant flow rate that is maintained via high precision mechanical pumps while a pulling force is applied through a potential difference that is applied between the nozzle and the ground electrode and as a result a fine jet can be generated to pattern surfaces. The impracticality of use and the cost of building micrometre and sub-micrometre sized nozzles to print narrow line widths warrant an investigation into alternative means of dispensing printing inks using nozzles that are cheap to produce, easy to handle and consistent in delivery. The enormous capillary pressures that would have to be overcome in order to print highly viscous materials with micrometre and sub-micrometre sized nozzles may also limit the types of feed that could be used in printing narrow line widths. Thus, the initial work described is focused on improving print head design in an attempt to electrohydrodynamic print pattern narrow line widths using silk fibroin. This is followed by work where we attempt to design and construct of a new electrohydrodynamic printing machine with the sole purpose of expediting research in electrohydrodynamic printing in a flexible, feasible and user friendly manner. To achieve this, replicating rapid prototype technology is merged with conventional electrohydrodynamic printing phenomena to produce a EHD printing machine capable of print depositing narrow line widths. In order to validate the device the work also describes an attempt to print a fully formed human ear out of polycaprolactone. Finally, we investigate an approach to the electohydrodynamic printing of nasal septal scaffolds using the microfabrication system that was developed and optimized in our laboratory. In these initial stages we were successful in showing the degree of control and flexibility we possess when manufacturing constructs out of a biodegradable polymer ( polycaprolactone) from the micro to macro scale through manipulation of just one process parameter (concentration). This work also features characterization of scaffold mechanical properties using a recently invented Atomic force microscopy technique called PeakForce QNM (Quantitative Nanomechanical Property Mapping)

Rational Design of Flexible and Stretchable Electronics based on 3D Printing

Flexible and stretchable electronics have been considered as the key component for the next generation of flexible devices. There are many approaches to prepare the devices, such as dip coating, spin coating, Mayer bar coating, filtration and transfer, and printing, etc. The effectiveness of these methods has been proven, but some drawbacks cannot be ignored, such as lacking pattern control, labor consuming, requiring complex pretreatment, wasting conductive materials, etc. In this investigation, we propose to adopt 3D printing technology to design flexible and stretchable electronics. The objective is to rationally design flexible and stretchable sensors, simplify the preparation process, form the sample with the complex desirable patterns, and promote the performance of the samples. The dissertation comprises of three major parts: water-induced polymer swelling and its application in soft electronics, utilizing 3D printing to transfer conductive layer into elastomer for building soft electronics, and 3D printing of functional devices. In the first part, we developed the soft electronics with wrinkled structure via 3D printing and water-induced polymer swelling, which can avoid some disadvantages in conventional method, e.g., pre-stretching and organic solvent-induced polymer swelling, including mechanical loss, negative effect to human health, and unidirectionally response to external deformation. Water-induced polymer swelling was achieved by introducing soluble particles into silicone matrixes and soaking the polymer composites in aqueous solution. We have investigated the characteristics and mechanisms of water-induced polymer swelling. Then, the conductive materials were deposited on the swollen sample to form the desired wrinkled structures for stretchable sensors. Furthermore, a dopamine layer was adopted to enhance the adhesion of matrix and conductive layer. The improvement was a key enabler to achieve superior electrical properties of 3D printed stretchable sensors for long-term cyclic stretching. We have demonstrated a series of human motion detection by using these stretchable strain sensors. Another part is designing flexible electrodes with desirable complex pattern by transferring a conductive layer into soft substrates during a 3D printing process. Taking advantage of extrusion pressure and polymer adhesion, the thin conductive layers were embedded into the printed polymer patterns, which can achieve conductive flexible electronics with desirable complex patterns. High-quality transfer has been achieved through adjusting conductive layer thickness, nozzle-to-substrate distance, and printing parameters, etc. Moreover, various printing patterns were created, and their properties were exhibited. The stretchable sensors showed an outstanding stress-strain relationship and electrical response to external deformations. The third part is about 3D printing of functional devices. In the collaborated study, the drug particles were introduced into silicone matrix to prepare the drug-eluting devices. When water molecules transported into the silicone matrix, the loaded drug particles decomposed and released nitric oxide (NO) enabling antibacterial properties. It is noted that 3D printing is creatively employed to form the desirable patterns. We also observed a self-wiring effect in the printing process, i.e., the printed device is covered by a drug-free layer due to the diffusion of a low viscosity silicone component during printing, which can be utilized to prevent drug release bursts and to form a gradient drug-loaded device. The printed samples showed a sustainable NO release and good antibacterial property. Furthermore, the water-induced polymer swelling was possible to be used as actuator in humidity environment. There are some highlights deserving emphasis in the dissertation. Firstly, the water-induced polymer swelling is proposed to develop the flexible and stretchable electronics. The findings have a wide potential application. Additionally, a drug-eluting polymer device with a drug-loaded bulk and a drug-free coating is prepared via leveraging self-wiring effect in 3D printing. The structure can regulate the drug release rate. On the other hand, the additive manufacturing platform offers unique opportunities to produce drug-eluting silicone devices in a customized manner. Finally, 3D printing is employed to encapsulate the conductive layers to achieve the flexible electronics with patterned structure and high performances. The facile and effective approach provides a distinctive view in advancing the development of stretchable electronics

Flexible and Stretchable Electronics

Flexible and stretchable electronics are receiving tremendous attention as future electronics due to their flexibility and light weight, especially as applications in wearable electronics. Flexible electronics are usually fabricated on heat sensitive flexible substrates such as plastic, fabric or even paper, while stretchable electronics are usually fabricated from an elastomeric substrate to survive large deformation in their practical application. Therefore, successful fabrication of flexible electronics needs low temperature processable novel materials and a particular processing development because traditional materials and processes are not compatible with flexible/stretchable electronics. Huge technical challenges and opportunities surround these dramatic changes from the perspective of new material design and processing, new fabrication techniques, large deformation mechanics, new application development and so on. Here, we invited talented researchers to join us in this new vital field that holds the potential to reshape our future life, by contributing their words of wisdom from their particular perspective

Alternative materials for flexible transparent conductive electrodes

This thesis investigates new alternative materials for flexible transparent electrodes: monolayer graphene and micron-scale metal mesh structures. Growth of graphene on copper foils by chemical vapour deposition (CVD) was investigated by commissioning and developing a CVD system in Tyndall. Initial growth runs resulted in poor graphene coverage. Several routes for growth improvement were examined: an acid pre-treatment, substrate geometry and growth pressure. Following this improvement, a continuous growth run was carried out displaying high monolayer graphene coverage. Graphene was transferred to Si/SiO2 (90 nm thermal oxide) and glass substrates using a wet chemical transfer process. This process involves the use of a polymer which acts as a support mechanism. However, polymer residue can have drastic effects on the electrical performance of CVD graphene films. Therefore an alternative method for polymer removal with the use of heated acetone (~ 60 oC) was investigated. Micron-scale platinum mesh structures were fabricated on rigid glass substrates using a range of metal deposition techniques; metal evaporation and lift-off; ALD and dry etching and sputter deposition and dry etching. Square, hexagonal, circular and a new asymmetric pentagonal tiling were utilised as metal meshes. Their performance were investigated along with the metal deposition technique. Evaporation and lift-off provided the most consistent technique in relation to transparency, haze and sheet resistance. Finally, asymmetric pentagonal platinum meshes were fabricated on flexible transparent substrates using metal evaporation and lift-off. All designs were bent around a radius of curvature (in air) of ~ 3.8 mm up to 1,000 bending cycles for both tension and compression and suggested good performance in comparison to literature. All three designs were used as transparent heaters via Joule heating. All heaters demonstrated good thermal characteristics such as low response times and high thermal resistances. Finally, a pentagonal metal mesh was used to de-ice a glass substrate

Microfabricated All-Around-Electrode AC Electro-osmotic Micropump

This thesis presents the fabrication and characterisation of AC electro-osmotic micropumps with a simple design and velocity generation enhanced by about four times with respect to devices with simpler designs. Electro-osmosis is a convenient and effective method to pump liquids without the need for moving components. The implementation of valveless micropumps is important for the realisation of safe and robust biomedical devices, which require long-term reliability. AC electro-osmosis has the advantage, over other kinds of pumping strategies, of being implementable with relatively simple geometries and fabrication processes. Moreover, it uses low voltages and avoids undesired phenomena such as electrolysis, thus being suitable for the implementation in implantable devices that should operate in a closed environment. Whereas AC electro-osmotic pumps presented in the literature exploit planar electrode designs and fail to generate good values of velocity and pressure, the prototypes presented in this work have electrodes patterned all around the pumping channel and can generate much larger values. Moreover, with respect to other improved prototypes based on 3D electrode geometries, our devices are simpler to fabricate and give comparable enhancements of the performances. In this work, we present the development of the all-around-electrode devices and give a theoretical explanation for the measured improvements in velocity generation. The fabrication process is carried out in the cleanroom by depositing Ti/Pt electrodes on pre-structured Pyrex substrates and requires only three lithographic steps. The performances of the fabricated devices are characterised as a function of the applied voltage and frequency, and the dynamic behaviour of the prototypes is studied using the Fourier transform. In order to evaluate the suitability of the pumps for biomedical fluids, the dependence of velocity generation on the concentration of the pumped solution is also addressed. Finally, we show that the fabrication process can be adapted to an industrial batch manufacture requiring lower costs by substituting the Pyrex substrates with thin plastic foils. All-around-electrode micropumps can be successfully fabricated by patterning metal electrodes onto 12-µm-thick plastic foils and the costs might be further reduced by substituting the metal structures with inkjet-printed conductive-polymer electrodes

Measurements of conductive film

This thesis was submitted for the award of Doctor of Philosophy and was awarded by Brunel University LondonPrinted electronics is a combination of electronics and printing technologies commonly used in the publication industry such as screen, inkjet, and roll to roll printing. The measurements of conductive film particularly the conductive paste is the main objective of this thesis. The conductive paste consists of conductive filler, adhesive and solvent. Each component affects the electrical, and mechanical properties of the finished conductive film product. The measurements of conductive film have three field of study. The first category is the lifetime performance measurement of conductive film using environmental testing. A screen printed carbon, silver and a developmental paste were categorised to environmental testing and third harmonic measurement. The second category is the measurement AC Impedance and DC resistance of conductive ink during cure. During the curing of the pastes, the AC impedance and DC resistance were monitored. A LabVIEW program was developed to control the AC impedance analyser, DC resistance ohmmeter, and convection oven. Samples were measured whilst curing at different curing temperatures and for a range of particle loadings. Particle loading is the percentage of conductive filler against the rest of the chemical in the conductive paste. The last category was defect detection using the combination of electromechanical testing, a Scanning Electron Microscope (SEM) and an Infrared (IR) imaging technique. Printed carbon and silver were mechanically aged by bending the printed structure up to 100 k times. The results from the lifetime performance measurements on carbon, silver and the developmental paste showed the polymer resin behaviour in high humidity and high temperature environments. The increased oxidation rate due to the elevated temperatures affected the conductive particle of certain pastes. The third harmonic testing technique was able to detect failures on conductive film in the form of width reduction. The AC impedance measurement technique could indicate the final resistivity value. The AC impedance measurement was affected by the test frequency used while the ink is in liquid state. Correct test frequency setting will have less noise and less impedance value, vital in predicting the final cured resistance of the printed paste. The curing temperature affects the final cured resistance value while the particle loading affects the rate of curing of conductive film. The electrical measurement on mechanically aged samples showed that the carbon prints have its resistance readings below its initial value while the silver prints resistance increased. SEM images shows that the carbon print indicates no visual damage on the surface after 100 k bent cycle, while physical defects were observed in silver prints. The infrared measurements on carbon prints showed an increase in temperature while developments of heat patches were observed on silver prints. Difference in emissivity values of materials used provided the contrast effect which plays an important role in detecting defect using infrared imaging technique because. Third harmonic application to the printed electronics is new to this field. Normally, testing is done using environmental testing to determine the lifetime performance of the conductive film. This is effective however requires a lot of time and effort to produce a result. AC Impedance is used widely and the application can be seen on cured printed electronics. The application and measurement of AC impedance during cure and DC resistance measurement has indicated initial resistivity values. The measurement has further the effect of using AC impedance on different curing temperature and particle loading. The phase measurement as well has brought insight of degree of curing. The application of infra-red imaging technique to the mechanically aged device has produced a result that DC resistance and SEM imaging failed to detect. Normally DC resistance measurement was used as quality assessment tool but test shows on mechanically aged product failed to detect increase in resistance due to mechanical aging techqnique

21st Century Nanostructured Materials

Nanostructured materials (NMs) are attracting interest as low-dimensional materials in the high-tech era of the 21st century. Recently, nanomaterials have experienced breakthroughs in synthesis and industrial and biomedical applications. This book presents recent achievements related to NMs such as graphene, carbon nanotubes, plasmonic materials, metal nanowires, metal oxides, nanoparticles, metamaterials, nanofibers, and nanocomposites, along with their physical and chemical aspects. Additionally, the book discusses the potential uses of these nanomaterials in photodetectors, transistors, quantum technology, chemical sensors, energy storage, silk fibroin, composites, drug delivery, tissue engineering, and sustainable agriculture and environmental applications

Electrohydrodynamic focusing and light propagation in 2-dimensional microfluidic devices for preconcentration of low abundance bioanalytes

This thesis presents work on electrohydrodynamic focusing (EHDF) and photon transmission to aid the development of species preconcentration and identification. EHDF is an equilibrium focusing method, where a target ion becomes stationary under the influence of a hydrodynamic force opposed by an electromigration force. To achieve this one force must have a non-zero gradient. In this research a novel approach of using a 2-dimensional planar microfluidic device is presented with an open 2D-plane space instead of conventional microchannel system. Such devices can allow pre-concentration of large volume of species and are relatively simple to fabricate. Fluid flow in these systems is often very complex making computer modelling a very useful tool. In this research, results of newly developed simulations using COMSOL Multiphysics® 3.5a are presented. Results from these models were compared to experimental results to validate the determined flow geometries and regions of increased concentration. The developed numerical microfluidic models were compared with previously published experiments and presented high correspondence of the results. Based on these simulations a novel chip shapes were investigated to provide optimal conditions for EHDF. The experimental results using fabricated chip exceeded performance of the model. A novel mode, named lateral EHDF, when test substance was focused perpendicularly to the applied voltage was observed in the fabricated microfluidic chip. As detection and visualisation is a critical aspect of such species preconcentration and identification systems. Numerical models and experimental validation of light propagation and light intensity distribution in 2D microfluidic systems was examined. The developed numerical mode of light propagation was used to calculate the actual light path through the system and the light intensity distribution. The model was successfully verified experimentally in both aspects, giving results that are interesting for the optimisation of photopolymerisation as well as for the optical detection systems employing capillaries

NASA Tech Briefs, October 2002

Topics include: a technology focus on sensors, electronic components and systems, software, materials, materials, mechanics, manufacturing, physical sciences, information sciences, book and reports, motion control and a special section of Photonics Tech Briefs

Micro/Nano Structures and Systems

Micro/Nano Structures and Systems: Analysis, Design, Manufacturing, and Reliability is a comprehensive guide that explores the various aspects of micro- and nanostructures and systems. From analysis and design to manufacturing and reliability, this reprint provides a thorough understanding of the latest methods and techniques used in the field. With an emphasis on modern computational and analytical methods and their integration with experimental techniques, this reprint is an invaluable resource for researchers and engineers working in the field of micro- and nanosystems, including micromachines, additive manufacturing at the microscale, micro/nano-electromechanical systems, and more. Written by leading experts in the field, this reprint offers a complete understanding of the physical and mechanical behavior of micro- and nanostructures, making it an essential reference for professionals in this field