Printing Functional Materials

Transcription

1 Printing Functional Materials Jennifer A. Lewis and Scott C. Slimmer Harvard School of Engineering and Applied Sciences Wyss Institute for Biologically Inspired Engineering

2 New materials are needed to enable functional parts Form significant improvements to multi-material technology is the breakthrough that is required. Jeffries Report 2013 Integrating electronics into a part and printing both simultaneously could forever change the way some products are designed and manufactured. Wohlers Report 2013 Function

3 Our overarching focus Broaden materials palette for 3D printing Co-print multiple materials Integrate form and function Improve feature resolution by 100x Improve throughput by 100x expedite transformation from rapid prototyping to manufacturing of advanced materials

4 Functional inks for 3D printing Key Criteria: ink must flow through nozzle without jamming ink must solidify rapidly concentrated inks minimize shrinkage during drying ceramic inks wax inks conductive inks polymer inks sol-gel inks 250 m 250 nm decreasing feature size

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6 Custom-designed 3D printers Moderate Area High Precision Printer Large Area High Speed Printer 10x10x5 cm 3 ± 50 nm 1m 2 x10 cm ± 5 m V = mm/s V = mm/s

7 Large-Area, Multimaterial 3D Printer Printer design: - built by Aerotech to our specs Key Attributes: - Filamentary ink deposition - Four ink heads

8 Large-Area, Multimaterial 3D Printer four dyed PDMS inks DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials, (2014)

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11 Silver inks for 3D printed electronics 20 nm average, 5 50 nm distribution Ahn, Duoss, Nuzzo, Rogers, Lewis, et al., Science (2009); Ahn, Duoss, and Lewis, US-Patent 7,922,939

12 Silver inks for 3D printed electronics Silver inks are highly conductive as-printed Ahn, Duoss, Nuzzo, Rogers, Lewis, et al., Science (2009); Ahn, Duoss, and Lewis, US-Patent 7,922,939 Russo et al., Advanced Materials (2011)

13 Silver inks for 3D printed electronics 1 m nozzle 5 m nozzle 10 m nozzle 5 m nozzle 30 m nozzle 10 m nozzle 5 m nozzle 10 m nozzle 30 m nozzle Ahn, Duoss, Nuzzo, Rogers, Lewis et al. Science (2009). Ahn, Duoss, and Lewis, US-Patent 7,922,939

14 Conformal printing of electrically small antennas copper-backed substrate conductive epoxy 8-arm antenna silver Electrodes (100 m) feed point glass Support 25.8 mm diameter ka = 0.41 with Bernhard group Illinois) k 2 0 ka < 0.5 indicates an electrically small antenna (ESA) Adams, Duoss, Malkowski, Ahn, Nuzzo, Bernhard, Lewis, Advanced Materials (2011)

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16 Performance characteristics BW ~ 14.3% Resonant at ~1.7 GHz Concave antenna Efficiency ~71% VSWR: a measure of signal reflected at component junctions Ideally, VSWR = 1 (no reflected power, no mismatch loss) Adams, Duoss, Malkowski, Ahn, Nuzzo, Bernhard, Lewis, Advanced Materials (2011)

17 Embedded 3D printing of stretchable sensors Carbon-based conductive ink is printed within a highly elastic matrix

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19 Stretchable sensors for biomedical, soft robotics, and athletics > 400% strain is possible

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21 Stretchable sensors for biomedical, soft robotics, and athletics Highly stretchable, multilayer pressure + strain sensors

22 3D printing of Li ion microbatteries For autonomous devices that: 1) Harvest energy 2) Store and deliver energy 3) Perform function Lai et al., Adv. Mater X Our goal: device Print 3D microbatteries (>1 mm 3 ) i.e., size of a single grain of sand (!) battery Warneke et al., Computer 2001

23 3D printing of Li ion microbatteries a) b) Nozzle Current (30 m) collector (Au) LTO LTO ink (anode) Glass c) LTO LFP d) Packaging LFP ink (cathode) K. Sun,T.-S. Wei, B.Y. Ahn, Lewis, Dillon et al, Adv. Mater. (2013)

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25 3D printing of Li ion microbatteries Battery ink printing 1 mm Sand grains each microbattery equivalent in size to a single grain of sand

26 Printed and packaged 3D microbattery 200 m Li ion microbatteries exhibit excellent energy and power densities K. Sun,T.-S. Wei, B.Y. Ahn, Lewis, Dillon et al, Adv. Mater. (2013)

27 Microbattery Performance Ref 34: Chiang (MIT) 3D-IMA (Lewis, Dillon) Ref 37: Braun, King (UIUC) areal densities 1 st gen printed batteries exhibit exceptional performance!

28 Scalable Li Ion Microbatteries New scalable process to create custom batteries for pick-and-place 3D printing

29 New materials are needed to enable living tissue printing Form significant improvements to multi-material technology is the breakthrough that is required. Jeffries Report 2013 Function

30 Hard scaffolds for tissue engineering Hydroxyapatite Scaffolds Silk-Hydroxyapatite Scaffolds 0.8mm (cancellous bone) Michna, Wu, Lewis, Biomaterials (2005); Simon et al, JBMR (2007) 0.4mm (compact bone) 1mm Sun, Lewis, Kaplan, et al. Adv. Healthcare Mat. (2012) 3D rendering of micro-ct scan 3D model of implant Printed scaffold After immersion, still wet condition Lewis, Smay, Stuecker, Cesarano, J. Am. Ceram. Soc. (2006)

31 Soft scaffolds for tissue engineering Polyelectrolyte Scaffolds Hydrogel Scaffolds 10 m 20 m 20 m G. Gratson, M. Xu, J.A. Lewis, Nature (2004). Silk Fibroin Scaffolds Ghosh et al. Adv. Funct. Mater. (2008). Shepherd, et al., Adv. Mater. (2011).

32 3D bioprinting of living tissue constructs unit cell Hydrogel ink (ECM) Fugitive ink (vasculature) Cell-laden Ink(s) Targeted applications: drug screening, tissue engineering, and organ repair

33 Fugitive and cell-laden inks Inks exhibit complimentary fluid-to-gel transitions

34 3D printing of cell-laden inks: Cell viability GFP fibroblasts in printed filaments 4x DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials (2014)

35 Printing 1D, 2D, 3D vascular networks 1-D 2-D 3-D DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials (2014)

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37 3D bioprinting of vascularized tissue constructs Interpenetrating network of cell-laden filaments and vascular channels DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials (2014)

38 3D bioprinting of vascularized tissue constructs GFP HNDFs RFP HUVECs 10T1/2 MFs Top view Side view Simple 4-layer construct to aid visualization Co-printing fugitive and cell-laden inks 500 µm DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials (2014)

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41 Vascularized living tissue constructs GFP HNDFs RFP HUVECs 10T1/2 MFs 500 µm DB Kolesky, R Truby, S Gladman, T Busbee, K Homan, and JA Lewis, Advanced Materials (2014)

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43 3D printed light-weight lattices Compton and Lewis (unpublished)

44 High throughput printing of 3D architectures Periodic polymer foam 3D Interpenetrating Architectures Dual multinozzle printhead 8-nozzle array Large-area (1 m 2 ) 3D structures printed in minutes using multinozzle printheads

45 High throughput printing of 3D architectures Periodic polymer foam 8-nozzle array Large-area (1 m 2 ) 3D structures printed in minutes using multinozzle printheads

46 3D Printing: Integrating form + function