Additive Manufacturing is capable of producing highly complex and personalised products. However, innovation in both material science and processing is required to achieve the performance, reliability and miniaturization of modern mass-produced electronic systems. This article presents a new digital fabrication strategy that combines 3D printing of high-performance polymers (polyetherimide) with light-based selective metallisation of copper traces through chemical modification of the polymer surface, and computer-controlled assembly of functional devices and structures. Using this approach, precise and robust conductive circuitry is fabricated across flexible and conformal surfaces omitting the need to connect and assemble separate circuits. To show how this process is compatible with existing electronic packaging techniques a range of modern components are solder surface mount assembled to selectively metalized bond pads. To highlight the potential applications stemming from this new capability, high frequency wireless communications, inductive powering and positional sensing demonstrators are manufactured and characterised. Furthermore, the incorporation of actuation is achieved through selective heating of shape memory alloys with a view towards routes towards folding and deployable 3D electronic systems. The results in this paper show how this process provides the required mechanical, electrical, thermal and electromagnetic properties for future real-world applications in the field of robotics, medicine, and wearable technologies.
Abstract 3D objects with integrated electronics are produced using an additive manufacturing approach relying on multiphoton fabrication (direct laser writing, (DLW)). Conducting polymer‐based structures (with micrometer‐millimeter scale features) are printed within exemplar matrices, including an elastomer (polydimethylsiloxane, (PDMS)) have been widely investigated for biomedical applications. The fidelity of the printing process in PDMS is assessed by optical coherence tomography, and the conducting polymer structures are demonstrated to be capable of stimulating mouse brain tissue in vitro. Furthermore, the applicability of the approach to printing structures in vivo is demonstrated in live nematodes ( Caenorhabditis elegans ). These results highlight the potential for such additive manufacturing approaches to produce next‐generation advanced material technologies, notably integrated electronics for technical and medical applications (e.g., human‐computer interfaces).
3D-structured NMC622 with precisely controlled electrolyte channels were manufactured by incorporating femtosecond laser processing with conventional slurry casting. Demonstrated in a full cell for the first time, the 3D electrode structures mitigate plating and dendrite growth at the graphite electrode and lead to improved cycling performance, 75% capacity retention vs 58% after 500 cycles. 3D-structured NMC622 with a high areal capacity, 5.6 mAh cm-2, exhibits a areal capacity retention of ~70% and volumetric capacity exceeding 250 mAh cm-3 at ~1.15C, three times and twice that of a conventional slurry-casted NMC622, respectively. The improved rate performance is attributed to the enhanced ionic transport and reduced charge transfer resistance facilitated by the 3D electrode structure, as shown through galvanostatic titration measurements. A finite element method-based 3D model illustrated the improved uniform distribution of Li-ion concentration and state of charge within the 3D-structured electrode. Additionally, the 3D electrode structure proved beneficial for wettability and accelerated electrolyte absorption, leading to improved manufacturing efficiency.
3D-structured NMC622 with precisely controlled electrolyte channels were manufactured by incorporating femtosecond laser processing with conventional slurry casting. Demonstrated in a full cell for the first time, the 3D electrode structures mitigate plating and dendrite growth at the graphite electrode and lead to improved cycling performance, 75% capacity retention vs 58% after 500 cycles. 3D-structured NMC622 with a high areal capacity, 5.5 mAh cm−2, exhibits a areal capacity retention of ∼70% and volumetric capacity exceeding 250 mAh cm−3 at ∼1.15C, three times and twice that of a conventional slurry-casted NMC622, respectively. The improved rate performance is attributed to the enhanced ionic transport and reduced charge transfer resistance facilitated by the 3D electrode structure, as shown through galvanostatic titration measurements. A finite element method-based 3D model illustrated the improved uniform distribution of Li-ion concentration and state of charge within the 3D-structured electrode. Additionally, the 3D electrode structure proved beneficial for wettability and accelerated electrolyte absorption, leading to improved manufacturing efficiency.
This study investigates the performance of geometrically defined dimple and groove textures in the turning of Al2024. On-machine testing using combinations of periodic SEM imaging and cutting force capture were used for wear assessments of the textured surfaces and to provide input data for tribology testing. Tribometer investigations were conducted to determine the influences of surface textures on elastohydrodynamic lubrication, influenced by tool-chip contact pressure and entrainment area. The study has shown that both dimple and groove textures can reduce surface friction by influencing mixed and hydrodynamic contact, resulting in reductions of cutting forces.
For some professionally, vocationally, or technically oriented careers, curricula delivered in higher education establishments may focus on teaching material related to a single discipline. By contrast, multidisciplinary, interdisciplinary, and transdisciplinary teaching (MITT) results in improved affective and cognitive learning and critical thinking, offering learners/students the opportunity to obtain a broad general knowledge base. Chemistry is a discipline that sits at the interface of science, technology, engineering, mathematics, and medicine (STEMM) subjects (and those aligned with or informed by STEMM subjects). This article discusses the significant potential of inclusion of chemistry in MITT activities in higher education and the real-world importance in personal, organizational, national, and global contexts. It outlines the development and implementation challenges attributed to legacy higher education infrastructures (that call for creative visionary leadership with strong and supportive management and administrative functions), and curriculum design that ensures inclusivity and collaboration and is pitched and balanced appropriately. It concludes with future possibilities, notably highlighting that chemistry, as a discipline, underpins industries that have multibillion dollar turnovers and employ millions of people across the world.
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