Mechanics and applications of stretchable serpentine structures

Stretchable structures have been developed for various applications, including expandable coronary stents, deployable sensor networks and stretchable bio-mimetic and bio-integrated electronics. High-performance, stretchable electronics have to utilize high-quality and long-lasting inorganic electronic materials such as silicon, oxide dielectrics and metals, which are intrinsically stiff and often brittle. It is therefore an interdisciplinary challenge to make inorganic electronics stretchable while retaining their electronic functionality. Patterning stiff materials into serpentine-shaped wavy ribbons has become a popular strategy for fabricating stretchable inorganic electronics. However due to a lack of mechanics understanding, design of serpentine structures is still largely empirical, whether for freestanding or substrate supported serpentines. This dissertation systematically investigates the mechanics of serpentine structures with emphasis on the effects of serpentine geometry and substrate stiffness, which involves theoretical analysis, numerical simulation, and experimental validation. Our theory has successfully predicted the stretchability and stiffness of various serpentine shapes and has been applied to the optimization of serpentine designs under practical constraints. We are also the first to point out that not all geometric effects are monotonic and serpentines are not always more stretchable than linear ribbons. To manufacture high quality serpentine ribbons with high throughput and low cost, we have invented a “cut-and-paste” method to fabricate both metallic and ceramic serpentines. As a demonstration of our method, a noninvasive, tattoo-like multifunctional epidermal sensor system has been built for the measurement of electrophysiological signals, skin temperature, skin hydration, and respiratory rate. Engineering of epidermal stretchable antenna for wireless communication is also detailed and rationalized.Mechanical Engineerin

3D printed neuromorphic sensing systems

Thanks to the high energy efficiency, neuromorphic devices are spotlighted recently by mimicking the calculation principle of the human brain through the parallel computation and the memory function. Various bio-inspired \u27in-memory computing\u27 (IMC) devices were developed during the past decades, such as synaptic transistors for artificial synapses. By integrating with specific sensors, neuromorphic sensing systems are achievable with the bio-inspired signal perception function. A signal perception process is possible by a combination of stimuli sensing, signal conversion/transmission, and signal processing. However, most neuromorphic sensing systems were demonstrated without signal conversion/transmission functions. Therefore, those cannot fully mimic the function provides by the sensory neuron in the biological system. This thesis aims to design a neuromorphic sensing system with a complete function as biological sensory neurons. To reach such a target, 3D printed sensors, electrical oscillators, and synaptic transistors were developed as functions of artificial receptors, artificial neurons, and artificial synapses, respectively. Moreover, since the 3D printing technology has demonstrated a facile process due to fast prototyping, the proposed 3D neuromorphic sensing system was designed as a 3D integrated structure and fabricated by 3D printing technologies. A novel multi-axis robot 3D printing system was also utilized to increase the fabrication efficiency with the capability of printing on vertical and tilted surfaces seamlessly. Furthermore, the developed 3D neuromorphic system was easily adapted to the application of tactile sensing. A portable neuromorphic system was integrated with a tactile sensing system for the intelligent tactile sensing application of the humanoid robot. Finally, the bio-inspired reflex arc for the unconscious response was also demonstrated by training the neuromorphic tactile sensing system

Materials, Mechanics, and Patterning Techniques for Elastomer-Based Stretchable Conductors

Stretchable electronics represent a new generation of electronics that utilize soft, deformable elastomers as the substrate or matrix instead of the traditional rigid printed circuit boards. As the most essential component of stretchable electronics, the conductors should meet the requirements for both high conductivity and the capability to maintain conductive under large deformations such as bending, twisting, stretching, and compressing. This review summarizes recent progresses in various aspects of this fascinating and challenging area, including materials for supporting elastomers and electrical conductors, unique designs and stretching mechanics, and the subtractive and additive patterning techniques. The applications are discussed along with functional devices based on these conductors. Finally, the review is concluded with the current limitations, challenges, and future directions of stretchable conductors

An optimized ultrasound detector for photoacoustic breast tomography

Photoacoustic imaging has proven to be able to detect vascularization-driven optical absorption contrast associated with tumors. In order to detect breast tumors located a few centimeter deep in tissue, a sensitive ultrasound detector is of crucial importance for photoacoustic mammography. Further, because the expected photoacoustic frequency bandwidth (a few MHz to tens of kHz) is inversely proportional to the dimensions of light absorbing structures (0.5 to 10+ mm), proper choices of materials and their geometries, and proper considerations in design have to be made for optimal photoacoustic detectors. In this study, we design and evaluate a specialized ultrasound detector for photoacoustic mammography. Based on the required detector sensitivity and its frequency response, a selection of active material and matching layers and their geometries is made leading to a functional detector models. By iteration between simulation of detector performances, fabrication and experimental characterization of functional models an optimized implementation is made and evaluated. The experimental results of the designed first and second functional detectors matched with the simulations. In subsequent bare piezoelectric samples the effect of lateral resonances was addressed and their influence minimized by sub-dicing the samples. Consequently, using simulations, the final optimized detector could be designed, with a center frequency of 1 MHz and a -6 dB bandwidth of ~80%. The minimum detectable pressure was measured to be 0.5 Pa, which will facilitate deeper imaging compared to the currrent systems. The detector should be capable of detecting vascularized tumors with resolution of 1-2 mm. Further improvements by proper electrical grounding and shielding and implementation of this design into an arrayed detector will pave the way for clinical applications of photoacoustic mammography.Comment: Accepted for publication in Medical Physics (American Association of Physicists in Medicine

Micro-Electro Discharge Machining: Principles, Recent Advancements and Applications

Micro electrical discharge machining (micro-EDM) is a thermo-electric and contactless process most suited for micro-manufacturing and high-precision machining, especially when difficult-to-cut materials, such as super alloys, composites, and electro conductive ceramics, are processed. Many industrial domains exploit this technology to fabricate highly demanding components, such as high-aspect-ratio micro holes for fuel injectors, high-precision molds, and biomedical parts.Moreover, the continuous trend towards miniaturization and high precision functional components boosted the development of control strategies and optimization methodologies specifically suited to address the challenges in micro- and nano-scale fabrication.This Special Issue showcases 12 research papers and a review article focusing on novel methodological developments on several aspects of micro electrical discharge machining: machinability studies of hard materials (TiNi shape memory alloys, Si3N4–TiN ceramic composite, ZrB2-based ceramics reinforced with SiC fibers and whiskers, tungsten-cemented carbide, Ti-6Al-4V alloy, duplex stainless steel, and cubic boron nitride), process optimization adopting different dielectrics or electrodes, characterization of mechanical performance of processed surface, process analysis, and optimization via discharge pulse-type discrimination, hybrid processes, fabrication of molds for inflatable soft microactuators, and implementation of low-cost desktop micro-EDM system

ELECTRO-TUNABLE OPTICAL DEVICES FOR MOLECULAR AND CELLULAR STUDIES

In the present scenario of information technology, researchers are looking for new systems able to deal more efficiently with the increasing amount of information produced by modern society. Nowadays, these tasks are accomplished by CMOS transistors and FLASH memories. Despite their wide implementation, these devices are facing serious issues along their road of development, mainly related to stable operation and power dissipation managing. Advancements in this field could boost the application of artificial intelligence and Big Data analysis, as well as enable new data communication protocols. By taking inspiration from the brain, a very powerful system characterized by low power consumption and high interconnectivity, new proposed devices, such as RRAM memories, aim at overcoming these issues. Properly engineered systems of this typology could act moreover as platforms for more precise and comprehensive biomedical studies. In this thesis, a new class of electro-tunable optical devices is presented in the framework of next-generation memory systems. The model device possesses very favorable characteristics, such as high density and interconnectivity. Moreover, the optical readout, performed by a camera, enables parallel operation. Two realizations of this device concept were studied. The first one is a new configuration for Zero-Mode Waveguides (ZMWs), a well-known nanophotonic system used to perform studies on fluorophore dispersion at the single molecule level. In the proposed device, the interplay of an electric voltage allows to control fluorophore concentration and residence time inside the ZMWs. The light intensity coming from the ZMWs gives information about these two parameters. In the second realization, the developed ZMWs platform is used to perform an optical detection of cardiomyocytes action potentials (APs). The cells are cultured on a thin substrate placed above the fluorophore dispersion. The substrate features an array of pass-through electrodes, which allow the electric APs to be transferred from the cells to the fluorophore dispersion. APs were successfully measured with high SNR. Moreover, the device proved able to detect the effects of a drug administered to the cell culture. This device could find application as a new system for in-vitro electrophysiology, including drugs cardiotoxicity studies. Due to the optical readout scheme, it promises to offer very high spatial resolution, orders of magnitude higher than conventional multi-electrode arrays systems

Strategies for neural control of prosthetic limbs: From electrode interfacing to 3D printing

Limb amputation is a major cause of disability in our community, for which motorised prosthetic devices offer a return to function and independence. With the commercialisation and increasing availability of advanced motorised prosthetic technologies, there is a consumer need and clinical drive for intuitive user control. In this context, rapid additive fabrication/prototyping capacities and biofabrication protocols embrace a highly-personalised medicine doctrine that marries specific patient biology and anatomy to high-end prosthetic design, manufacture and functionality. Commercially-available prosthetic models utilise surface electrodes that are limited by their disconnect between mind and device. As such, alternative strategies of mind-prosthetic interfacing have been explored to purposefully drive the prosthetic limb. This review investigates mind to machine interfacing strategies, with a focus on the biological challenges of long-term harnessing of the user\u27s cerebral commands to drive actuation/movement in electronic prostheses. It covers the limitations of skin, peripheral nerve and brain interfacing electrodes, and in particular the challenges of minimising the foreign-body response, as well as a new strategy of grafting muscle onto residual peripheral nerves. In conjunction, this review also investigates the applicability of additive tissue engineering at the nerve-electrode boundary, which has led to pioneering work in neural regeneration and bioelectrode development for applications at the neuroprosthetic interface

Design, evaluation, and control of nexus: a multiscale additive manufacturing platform with integrated 3D printing and robotic assembly.

Additive manufacturing (AM) technology is an emerging approach to creating three-dimensional (3D) objects and has seen numerous applications in medical implants, transportation, aerospace, energy, consumer products, etc. Compared with manufacturing by forming and machining, additive manufacturing techniques provide more rapid, economical, efficient, reliable, and complex manufacturing processes. However, additive manufacturing also has limitations on print strength and dimensional tolerance, while traditional additive manufacturing hardware platforms for 3D printing have limited flexibility. In particular, part geometry and materials are limited to most 3D printing hardware. In addition, for multiscale and complex products, samples must be printed, fabricated, and transferred among different additive manufacturing platforms in different locations, which leads to high cost, long process time, and low yield of products. This thesis investigates methods to design, evaluate, and control the NeXus, which is a novel custom robotic platform for multiscale additive manufacturing with integrated 3D printing and robotic assembly. NeXus can be used to prototype miniature devices and systems, such as wearable MEMS sensor fabrics, microrobots for wafer-scale microfactories, tactile robot skins, next generation energy storage (solar cells), nanostructure plasmonic devices, and biosensors. The NeXus has the flexibility to fixture, position, transport, and assemble components across a wide spectrum of length scales (Macro-Meso-Micro-Nano, 1m to 100nm) and provides unparalleled additive process capabilities such as 3D printing through both aerosol jetting and ultrasonic bonding and forming, thin-film photonic sintering, fiber loom weaving, and in-situ Micro-Electro-Mechanical System (MEMS) packaging and interconnect formation. The NeXus system has a footprint of around 4m x 3.5m x 2.4m (X-Y-Z) and includes two industrial robotic arms, precision positioners, multiple manipulation tools, and additive manufacturing processes and packaging capabilities. The design of the NeXus platform adopted the Lean Robotic Micromanufacturing (LRM) design principles and simulation tools to mitigate development risks. The NeXus has more than 50 degrees of freedom (DOF) from different instruments, precise evaluation of the custom robots and positioners is indispensable before employing them in complex and multiscale applications. The integration and control of multi-functional instruments is also a challenge in the NeXus system due to different communication protocols and compatibility. Thus, the NeXus system is controlled by National Instruments (NI) LabVIEW real-time operating system (RTOS) with NI PXI controller and a LabVIEW State Machine User Interface (SMUI) and was programmed considering the synchronization of various instruments and sequencing of additive manufacturing processes for different tasks. The operation sequences of each robot along with relevant tools must be organized in safe mode to avoid crashes and damage to tools during robots’ motions. This thesis also describes two demonstrators that are realized by the NeXus system in detail: skin tactile sensor arrays and electronic textiles. The fabrication process of the skin tactile sensor uses the automated manufacturing line in the NeXus with pattern design, precise calibration, synchronization of an Aerosol Jet printer, and a custom positioner. The fabrication process for electronic textiles is a combination of MEMS fabrication techniques in the cleanroom and the collaboration of multiple NeXus robots including two industrial robotic arms and a custom high-precision positioner for the deterministic alignment process