Emerging research on printed and flexible graphene-based electronics is beginning to show tremendous promise for a wide variety of fields including wearable sensors and thin film transistors. However, post-print annealing/reduction processes that are necessary to increase the electrical conductivity of the printed graphene degrade sensitive substrates (e.g., paper) and are whole substrate processes that are unable to selectively anneal/reduce only the printed graphene-leaving sensitive device components exposed to damaging heat or chemicals. Herein a pulsed laser process is introduced that can selectively irradiate inkjet printed reduced graphene oxide (RGO) and subsequently improve the electrical conductivity (Rsheet∼0.7 kΩ□(-1)) of printed graphene above previously published reports. Furthermore, the laser process is capable of developing 3D petal-like graphene nanostructures from 2D planar printed graphene. These visible morphological changes display favorable electrochemical sensing characteristics-ferricyanide cyclic voltammetry with a redox peak separation (ΔEp) ≈ 0.7 V as well as hydrogen peroxide (H2O2) amperometry with a sensitivity of 3.32 μA mM(-1) and a response time of <5 s. Thus this work paves the way for not only paper-based electronics with graphene circuits, it enables the creation of low-cost and disposable graphene-based electrochemical electrodes for myriad applications including sensors, biosensors, fuel cells, and theranostic devices.

Optoelectronic performance of metal nanowire networks are dominated by junction microstructure and network configuration. Although metal nanowire printings, such as silver nanowires (AgNWs) or AgNWs/semiconductor oxide bilayer, have great potential to replace traditional ITO, efficient and selective nanoscale integration of nanowires is still challenging owing to high cross nanowire junction resistance. Herein, pulsed laser irradiation under controlled conditions is used to generate local crystalline nanojoining of AgNWs without affecting other regions of the network, resulting in significantly improved optoelectronic performance. The method, laser-induced plasmonic welding (LPW), can be applied to roll-to-roll printed AgNWs percolating networks on PET substrate. First principle simulations and experimental characterizations reveal the mechanism of crystalline nanojoining originated from thermal activated isolated metal atom flow over nanowire junctions. Molecular dynamic simulation results show an angle-dependent recrystallization process during LPW. The excellent optoelectronic performance of AgNW/PET has achieved Rs ∼ 5 Ω/sq at high transparency (91% @λ = 550 nm).

Microneedle arrays show many advantages in drug delivery applications due to their convenience and reduced risk of infection. Compared to other microscale manufacturing methods, 3D printing easily overcomes challenges in the fabrication of microneedles with complex geometric shapes and multifunctional performance. However, due to material characteristics and limitations on printing capability, there are still bottlenecks to overcome for 3D printed microneedles to achieve the mechanical performance needed for various clinical applications. The hierarchical structures in limpet teeth, which are extraordinarily strong, result from aligned fibers of mineralized tissue and protein‐based polymer reinforced frameworks. These structures provide design inspiration for mechanically reinforced biomedical microneedles. Here, a bioinspired microneedle array is fabricated using magnetic field‐assisted 3D printing (MF‐3DP). Micro‐bundles of aligned iron oxide nanoparticles (aIOs) are encapsulated by polymer matrix during the printing process. A bioinspired 3D‐printed painless microneedle array is fabricated, and suitability of this microneedle patch for drug delivery during long‐term wear is demonstrated. The results reported here provide insights into how the geometrical morphology of microneedles can be optimized for the painless drug delivery in clinical trials.

A ceramic/graphene metamaterial (GCM) with microstructure-derived superelasticity and structural robustness is achieved by designing hierarchical honeycomb microstructures, which are composited with two brittle constituents (graphene and ceramic) assembled in multi-nanolayer cellular walls. Attributed to the designed microstructure, well-interconnected scaffolds, chemically bonded interface, and coupled strengthening effect between the graphene framework and the nanolayers of the Al O ceramic (NAC), the GCM demonstrates a sequence of multifunctional properties simultaneously that have not been reported for ceramics and ceramics-matrix-composite structures, such as flyweight density, 80% reversible compressibility, high fatigue resistance, high electrical conductivity, and excellent thermal-insulation/flame-retardant performance simultaneously. The 3D well-ordered graphene aerogel templates are strongly coupled with the NAC by the chemically bonded interface, exhibiting mutual strengthening, compatible deformability, and a linearly dependent relationship between the density and Young's modulus. Considerable size effects of the ceramic nanolayers on the mechanical properties are revealed in these ceramic-based metamaterials. The designed hierarchical honeycomb graphene with a fourth dimensional control of the ceramic nanolayers on new ways to scalable fabrication of advanced multifunctional ceramic composites with controllable design suggest a great potential in applications of flexible conductors, shock/vibration absorbers, thermal shock barriers, thermal insulation/flame-retardant skins, and porous microwave-absorbing coatings.

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Ongoing efforts in triboelectric nanogenerators (TENGs) focus on enhancing power generation, but obstacles concerning the economical and cost-effective production of TENGs continue to prevail. Micro-/nanostructure engineering of polymer surfaces has been dominantly utilized for boosting the contact triboelectrification, with deposited metal electrodes for collecting the scavenged energy. Nevertheless, this state-of-the-art approach is limited by the vague potential for producing 3D hierarchical surface structures with conformable coverage of high-quality metal. Laser-shock imprinting (LSI) is emerging as a potentially scalable approach for directly surface patterning of a wide range of metals with 3D nanoscale structures by design, benefiting from the ultrahigh-strain-rate forming process. Here, a TENG device is demonstrated with LSI-processed biomimetic hierarchically structured metal electrodes for efficient harvesting of water-drop energy in the environment. Mimicking and transferring hierarchical microstructures from natural templates, such as leaves, into these water-TENG devices is effective regarding repelling water drops from the device surface, since surface hydrophobicity from these biomicrostructures maximizes the TENG output. Among various leaves' microstructures, hierarchical microstructures from dried bamboo leaves are preferable regarding maximizing power output, which is attributed to their unique structures, containing both dense nanostructures and microscale features, compared with other types of leaves. Also, the triboelectric output is significantly improved by closely mimicking the hydrophobic nature of the leaves in the LSI-processed metal surface after functionalizing it with low-surface-energy self-assembled-monolayers. The approach opens doors to new manufacturable TENG technologies for economically feasible and ecologically friendly production of functional devices with directly patterned 3D biomimic metallic surfaces in energy, electronics, and sensor applications.

Selective deposition and preferential alignment of two-dimensional (2D) nanoparticles on complex and flexible three-dimensional (3D) substrates can tune material properties and enrich structural versatility for broad applications in wearable health monitoring, soft robotics, and human−machine interfaces. However, achieving precise and scalable control of the morphology of layer-structured nanomaterials is challenging, especially constructing hierarchical architectures consistent from nanoscale alignment to microscale patterning to complex macroscale landscapes. This work demonstrated a scalable and straightforward hybrid 3D printing method for orientational alignment and positional patterning of 2D MXene nanoparticles. This process involved (i) surface topology design via microcontinuous liquid interface production (μCLIP) and (ii) directed assembly of MXene flakes via capillarity-driven direct ink writing (DIW). With well-managed surface patterning geometry and printing ink quality control, the surface microchannels constrained MXene suspensions and leveraged microforces to facilitate preferential alignment of MXene sheets via layer-by-layer additive depositions. The printed devices displayed multifunctional properties, i.e., anisotropic conductivity and piezoresistive sensing with a wide sensing range, high sensitivity, fast response time, and mechanical durability. Our fabrication technique shows enormous potential for rapid, digital, scalable, and low-cost manufacturing of hierarchical structures, especially for micropatterning and aligning 2D nanoparticles not easily accessible through conventional processing methods.

3D printing (additive manufacturing (AM)) has enormous potential for rapid tooling and mass production due to its design flexibility and significant reduction of the timeline from design to manufacturing. The current state-of-the-art in 3D printing focuses on material manufacturability and engineering applications. However, there still exists the bottleneck of low printing resolution and processing rates, especially when nanomaterials need tailorable orders at different scales. An interesting phenomenon is the preferential alignment of nanoparticles that enhance material properties. Therefore, this review emphasizes the landscape of nanoparticle alignment in the context of 3D printing. Herein, a brief overview of 3D printing is provided, followed by a comprehensive summary of the 3D printing-enabled nanoparticle alignment in wellestablished and in-house customized 3D printing mechanisms that can lead to selective deposition and preferential orientation of nanoparticles. Subsequently, it is listed that typical applications that utilized the properties of ordered nanoparticles (e.g., structural composites, heat conductors, chemo-resistive sensors, engineered surfaces, tissue scaffolds, and actuators based on structural and functional property improvement). This review's emphasis is on the particle alignment methodology and the performance of composites incorporating aligned nanoparticles. In the end, significant limitations of current 3D printing techniques are identified together with future perspectives.