3D‐printed stents are fabricated with high speed and resolution by micro‐continuous liquid interface production (microCLIP) of a bioresorbable, antioxidant, photopolymerizable polydiolcitrate biomaterial. Printed stents can match the mechanical properties of bare metal stents and strengthen porcine arteries after deployment. This technology is a big step forward toward on‐the‐spot and on‐demand printing of patient‐specific stents.

Through finite element analysis and a 3D printing assisted experimental study, we demonstrate a design of mechanical metamaterials for simultaneous mechanical wave filtering and energy harvesting. The mechanical metamaterials compromise a square array of free-standing cantilevers featuring piezoelectric properties being attached to a primary structural frame. A complete bandgap has thus been created via the strong coupling of the bulk elastic wave propagating along the structural frame and the distributed local resonance associated with the square array of piezoelectrically active cantilevers. Operating within the stop-band, external vibration energy has been trapped and transferred into the kinetic energy of the cantilevers, which is further converted into electric energy through mechano-electrical conversion of its integrated piezoelectric elements. Therefore, two distinct functions, vibration isolation and energy harvesting, are achieved simultaneously through the designed mechanical metamaterials.

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The inefficiency in converting low frequency vibration (6~240 Hz) to electrical energy remains a key issue for miniaturized vibration energy harvesting devices. To address this subject, this paper reports on the novel, three-dimensional micro-fabrication of spring elements within such devices, in order to achieve resonances and maximum energy conversion within these common frequencies. The process, known as projection microstereolithography, is exploited to fabricate polymer-based springs direct from computer-aided designs using digital masks and ultraviolet-curable resins. Using this process, a micro-spring structure is fabricated consisting of a two-by-two array of three-dimensional, constant-pitch helical coils made from 1,6-hexanediol diacrylate. Integrating the spring structure into an electromagnetic device, with a magnetic load mass of 1.236 grams, the resonance is measured at 61 Hz, which is within 2% of the theoretical model. The device provides a maximum normalized power output of 9.14 μW/G (G=9.81 ms−2) and an open circuit normalized voltage output of 621 mV/G. To the best of the authors knowledge, notable features of this work include the lowest Young’s modulus (530 MPa), density (1.011 g/cm3), and “largest feature size” (3.4 mm) for a spring element in a vibration energy harvesting device with sub-100 Hz resonance.

Topological design of miniaturized resonating structures capable of harvesting electrical energy from low frequency environmental mechanical vibrations encounters a particular physical challenge, due to the conflicting design requirements: low resonating frequency and miniaturization. In this paper structural static stiffness to resist undesired lateral deformation is included into the objective function, to prevent the structure from degenerating and forcing the solution to be manufacturable. The rational approximation of material properties interpolation scheme is introduced to deal with the problems of local vibration and instability of the low density area induced by the design dependent body forces. Both density and level set based topology optimization (TO) methods are investigated in their parameterization, sensitivity analysis, and applicability for low frequency energy harvester TO problems. Continuum based variation formulations for sensitivity analysis and the material derivative based shape sensitivity analysis are presented for the density method and the level set method, respectively; and their similarities and differences are highlighted. An external damper is introduced to simulate the energy output of the resonator due to electrical damping and the Rayleigh proportional damping is used for mechanical damping. Optimization results for different scenarios are tested to illustrate the influences of dynamic and static loads. To demonstrate manufacturability, the designs are built to scale using a 3D microfabrication method and assembled into vibration energy harvester prototypes. The fabricated devices based on the optimal results from using different TO techniques are tested and compared with the simulation results. The structures obtained by the level set based TO method require less post-processing before fabrication and the structures obtained by the density based TO method have resonating frequency as low as 100 Hz. The electrical voltage response in the experiment matches the trend of the simulation data.

The inefficiency in converting naturally occurring vibration frequencies (sub-100 Hz) to electrical energy continues to be a major obstacle for miniaturized vibration energy harvesters. In a recent work, we addressed this issue by introducing photopolymer-based designs, using projection microstereolithography which exhibited 61 Hz resonant frequencies due to low elastic moduli and low flexural rigidity using a three-dimensional, helical coil design. In this paper, we extend upon those findings to report on a post-process technique which uses ultraviolet exposure time to manipulate the material properties of photopolymer-based vibration energy harvesters. The results show with 1–3 minutes of post-exposure, an effective elastic modulus variation from 399–904 MPa and a parasitic damping change from 0.0595–0.0986 kgs−1. Likewise, resonant frequency shifts of 53.5–805 Hz and power output increase from 56.5 to 120.4 μW (when excited at a constant acceleration of 6.06±0.06 ms−2) are achieved, without geometry changes and using the same photopolymer material.