Abstract:The mechanical properties of ordinary materials degrade substantially with reduced density, due to the bending of their structural elements under applied load. We report a class of micro-architected materials that maintain a nearly constant stiffness per unit mass density, even at ultra-low density. This performance derives from a network of nearly isotropic microscale unit cells with high structural connectivity and nanoscale features, whose structural members are designed to carry loads in tension or compression. Production of these microlattices, with constituent materials ranging from polymers to metals and ceramics, is made possible by using projection microstereolithography, an additive micromanufacturing technique, combined with nanoscale coating and postprocessing. We found that these materials exhibit ultra-stiff properties across more than three orders of magnitude in density, regardless of the constituent material. One Sentence Summary:We report a class of micro-architected materials that change their stiffness linearly with reduced density.Main Text: Nature has found a way to achieve mechanically efficient materials by evolving cellular structures. Natural cellular materials, including honeycomb (1) (wood, cork) and foamlike structures, such as trabecular bone (2), plant parenchyma (3), and sponge (4), combine low weight with superior mechanical properties. For example, lightweight balsa has a stiffness-toweight ratio comparable to that of steel along the axial loading direction (5). Inspired by these naturally occurring cellular structures, manmade lightweight cellular materials fabricated from a wide array of solid constituents are desirable for a broad range of applications including structural components (6, 7), energy absorption (8, 9), heat exchange (10, 11), catalyst supports (12), filtration (13,14), and biomaterials (15,16). However, the degradation in mechanical properties can be drastic as density decreases (17,18). A number of examples among recently reported low-density materials include graphene elastomers (19), metallic micro-lattices (20), carbon nanotube foams (21), and silica aerogels (22,23). For instance, the Young's modulus of low-density silica aerogels (22, 23) decreases to 10 kPa (10 -5 % of bulk ) at a density of less than 10 mg/cm 3 (< 0.5% of bulk). This loss of mechanical performance is because most natural and engineered cellular solids with random porosity, particularly at relative densities less than 0.1%, exhibit a quadratic or stronger scaling relationship between Young's modulus and density as well as between strength and density. Namely, E/E s ~ (/ s ) n and  y  ys ~ (/ s ) n , where E is Young's modulus,  is density,  y is yield strength, and s denotes the respective bulk value of the solid constituent material property. The power n of the scaling relationship between relative material density and the relative mechanical property depends on the material's microarchitecture. Conventional cellular foam materials with stochastic porosity are known to...

Materials with three-dimensional micro- and nanoarchitectures exhibit many beneficial mechanical, energy conversion and optical properties. However, these three-dimensional microarchitectures are significantly limited by their scalability. Efforts have only been successful only in demonstrating overall structure sizes of hundreds of micrometres, or contain size-scale gaps of several orders of magnitude. This results in degraded mechanical properties at the macroscale. Here we demonstrate hierarchical metamaterials with disparate three-dimensional features spanning seven orders of magnitude, from nanometres to centimetres. At the macroscale they achieve high tensile elasticity (>20%) not found in their brittle-like metallic constituents, and a near-constant specific strength. Creation of these materials is enabled by a high-resolution, large-area additive manufacturing technique with scalability not achievable by two-photon polymerization or traditional stereolithography. With overall part sizes approaching tens of centimetres, these unique nanostructured metamaterials might find use in a broad array of applications.

Three‐dimensional printing of viscoelastic inks to create porous, elastomeric architectures with mechanical properties governed by the ordered arrangement of their sub‐millimeter struts is reported. Two layouts are patterned, one resembling a “simple cubic” (SC)‐like structure and another akin to a “face‐centered tetragonal” (FCT) configuration. These structures exhibit markedly distinct load response with directionally dependent behavior, including negative stiffness. More broadly, these findings suggest the ability to independently tailor mechanical response in cellular solids via micro‐architected design. Such ordered materials may one day replace random foams in mechanical energy absorption applications.

A new approach for ultrarapid 3D manufacturing creates complex aperiodic volumes in a single step.

The rapid manufacture of complex three-dimensional micro-scale components has eluded researchers for decades. Several additive manufacturing options have been limited by either speed or the ability to fabricate true three-dimensional structures. Projection micro-stereolithography (PμSL) is a low cost, high throughput additive fabrication technique capable of generating three-dimensional microstructures in a bottom-up, layer by layer fashion. The PμSL system is reliable and capable of manufacturing a variety of highly complex, three-dimensional structures from micro- to meso-scales with micro-scale architecture and submicron precision. Our PμSL system utilizes a reconfigurable digital mask and a 395 nm light-emitting diode (LED) array to polymerize a liquid monomer in a layer-by-layer manufacturing process. This paper discusses the critical process parameters that influence polymerization depth and structure quality. Experimental characterization and performance of the LED-based PμSL system for fabricating highly complex three-dimensional structures for a large range of applications is presented.

We have fabricated a low-cost disposable polymerase chain reaction thermal chamber that uses buoyancy forces to move the sample solution between the different temperatures necessary for amplification. Three-dimensional, unsteady finite element modeling and a simpler 1-D steady-state model are used together with digital particle image velocimetry data to characterize the flow within the device. Biological samples have been amplified using this novel thermal chamber. Time for amplification is less than 30 min. More importantly, an analysis of the energy consumption shows significant improvements over current technology.

3D printing of polymeric foams by direct-ink-write is a recent technological breakthrough that enables the creation of versatile compressible solids with programmable microstructure, customizable shapes, and tunable mechanical response including negative elastic modulus. However, in many applications the success of these 3D printed materials as a viable replacement for traditional stochastic foams critically depends on their mechanical performance and micro-architectural stability while deployed under long-term mechanical strain. To predict the long-term performance of the two types of foams we employed multi-year-long accelerated aging studies under compressive strain followed by a time-temperature-superposition analysis using a minimum-arc-length-based algorithm. The resulting master curves predict superior long-term performance of the 3D printed foam in terms of two different metrics, i.e., compression set and load retention. To gain deeper understanding, we imaged the microstructure of both foams using X-ray computed tomography, and performed finite-element analysis of the mechanical response within these microstructures. This indicates a wider stress variation in the stochastic foam with points of more extreme local stress as compared to the 3D printed material, which might explain the latter’s improved long-term stability and mechanical performance.

We study the cyclic dynamics of a single polymer tethered to a hard wall in shear flow using Brownian dynamics, the lattice Boltzmann method, and a recent stochastic event-driven molecular dynamics algorithm. We focus on the dynamics of the free end (last bead) of the tethered chain and we examine the cross-correlation function and power spectral density of the chain extensions in the flow and gradient directions as a function of chain length N and dimensionless shear rate Wi. Extensive simulation results suggest a classical fluctuation-dissipation stochastic process and question the existence of periodicity of the cyclic dynamics, as previously claimed. We support our numerical findings with a simple analytical calculation for a harmonic dimer in shear flow.