Fabrication and Applications of Nature-Inspired Surfaces with Selective Wettability.

Inspired by the Stenocora beetle, selective wettability surfaces incorporate alternating wettable and nonwettable surface features that have received substantial attention over the past two decades. These surfaces are sought after for their very promising potential to drive progress in numerous application fields, including ecological protection, biomedical sciences, and industrial technologies. However, despite ongoing efforts to produce such surfaces in commercial quantities, understanding their basic fabrication concepts for practical applications can be challenging, especially for novices, given the vast technical literature in this area. This review, therefore, aims to elucidate the principles of wettability, along with the evolution of selective wettability surfaces and their uses. Beginning with a summary of the essential history and theory of wetting, we explore naturally occurring surfaces that have influenced wetting studies. We then detail state-of-the-art methods for fabricating these unique biwetting surfaces and show how contemporary science employs such designs in solving real-world problems. Finally, we offer an outlook for future research prospects on scalable, printing-based fabrication methods.

Achieving Selective Wettability Surface through Aerosol Jet Hydrophobic Line Printing.

Selective wettability surface patterning, involving the combination of wetting and nonwetting surface features in an alternating manner, has emerged as a key surface control technique with broad applications in cell microarrays, microfluidics, and drop placement. However, traditional approaches to creating such patterns often suffer material waste and rely on masking substrate surfaces with predesigned templates, resulting in elevated costs. Here, we present an approach to achieve selective wettability surface patterning using aerosol jet printing that offers a solution to these challenges. Our method involves the precise deposition of atomized, hydrophobic silica nanoparticle droplets onto substrate surfaces. By directing these atomized droplets, we created well-defined hydrophobic lines. The individual lines have an average width of 60 µm and a thickness of 1.32 µm, which, when overlaid, form a complete superhydrophobic surface with a water contact angle of 154°. The implications of these findings are substantial for various applications. We accordingly show the applicability of our method for confining drops and demonstrate on-target waterproofing of electronic circuit lines.

Fine conductive line printing of high viscosity CuO ink using near field electrospinning (NFES).

Modern printed electronics applications require patterning of fine conductive lines of sufficient thickness. However, the two requirements for pattern width and thickness are a trade-off. To print fine pattern at a micrometer size, the nozzle diameter must be approximately the size of the pattern width, so only low-viscosity inks are used. As a result, the pattern is likely to be very thin and multiple overlapping printing is required for sufficient conductance. In order to use high viscosity ink for fine patterning, near field electrospinning (NFES) is attracting attention because it can print very thin and thick patterns using large nozzles (high-viscosity ink). Until now, silver paste ink has been used for microconductive patterning using electrospinning. However, Ag nanoparticle (NP) inks are expensive. In this study, we report the use of a relatively inexpensive CuO NP ink for electrospinning-based printing. For implementation, the material preparation, printing and post-processing process are discussed. For post-processing, a continuous wave (CW) green laser with a 532 nm wavelength was used to reduce the CuO to Cu and sinter the nanoparticles. After sintering, the 50 µm width and 1.48 µm thick Cu conductive line exhibited a resistivity of 5.46 µΩ·cm, which is 3.25 times of the bulk resistivity of Cu.

Machine learning approach to monitor inkjet jetting status based on the piezo self-sensing.

One of the advantages of inkjet printing in digital manufacturing is the ability to use multiple nozzles simultaneously to improve the productivity of the processes. However, the use of multiple nozzles makes inkjet status monitoring more difficult. The jetting nozzles must be carefully selected to ensure the quality of printed products, which is challenging for most inkjet processes that use multi-nozzles. In this article, we improved inkjet print head monitoring based on self-sensing signals by using machine learning algorithms. Specifically, supervised machine learning models were used to classify nozzle jetting conditions. For this purpose, the self-sensing signals were acquired, and the feature information was extracted for training. A vision algorithm was developed to label the nozzle status for classification. The trained models showed that the classification accuracy is higher than 99.6% when self-sensing signals are used for monitoring. We also proposed a so-called hybrid monitoring method using trained machine learning models, which divides the feature space into three regions based on predicted jetting probability: certain jetting, certain non-jetting, and doubt regions. Then, the nozzles with uncertain status in the doubt region can be verified by jet visualization to improve the accuracy and efficiency of the monitoring process.

A Novel Strategy for Creating an Antibacterial Surface Using a Highly Efficient Electrospray-Based Method for Silica Deposition.

Adhesion of bacteria on biomedical implant surfaces is a prerequisite for biofilm formation, which may increase the chances of infection and chronic inflammation. In this study, we employed a novel electrospray-based technique to develop an antibacterial surface by efficiently depositing silica homogeneously onto polyethylene terephthalate (PET) film to achieve hydrophobic and anti-adhesive properties. We evaluated its potential application in inhibiting bacterial adhesion using both Gram-negative Escherichia coli (E. coli) and Gram-positive Staphylococcus aureus (S. aureus) bacteria. These silica-deposited PET surfaces could provide hydrophobic surfaces with a water contact angle greater than 120° as well as increased surface roughness (root mean square roughness value of 82.50 ± 16.22 nm and average roughness value of 65.15 ± 15.26 nm) that could significantly reduce bacterial adhesion by approximately 66.30% and 64.09% for E. coli and S. aureus, respectively, compared with those on plain PET surfaces. Furthermore, we observed that silica-deposited PET surfaces showed no detrimental effects on cell viability in human dermal fibroblasts, as confirmed by MTT (3-(4,5-dimethylthiazol-2-yl)-2,5 diphenyl tetrazolium bromide and live/dead assays. Taken together, such approaches that are easy to synthesize, cost effective, and efficient, and could provide innovative strategies for preventing bacterial adhesion on biomedical implant surfaces in the clinical setting.

High-Efficiency Electrospray Deposition Method for Nonconductive Substrates: Applications of Superhydrophobic Coatings.

When highly insulating materials are used as substrates for electronic devices, manufacturing yields become worse, and electronic components are often damaged due to undissipated electrostatic charges on such substrates. In the case of electrospray deposition, the problem of undissipated charges is particularly vexing. If charges accumulated on the substrate are not properly compensated, a repulsive force is generated against the incoming charged droplets, which negatively affects the uniformity and deposition rate of the coating layer. In order to overcome this limitation, we demonstrated a new electrospray method, which can significantly increase the deposition efficiency even in the presence of accumulated charges on nonconductive substrates. A highly reliable superhydrophobic layer was uniformly deposited on highly insulating substrates, including printed circuit board (PCB), polyester (PET), and polyimide (PI) substrates.

Printing Multi-Material Organic Haptic Actuators.

Haptic actuators generate touch sensations and provide realism and depth in human-machine interactions. A new generation of soft haptic interfaces is desired to produce the distributed signals over large areas that are required to mimic natural touch interactions. One promising approach is to combine the advantages of organic actuator materials and additive printing technologies. This powerful combination can lead to devices that are ergonomic, readily customizable, and economical for researchers to explore potential benefits and create new haptic applications. Here, an overview of emerging organic actuator materials and digital printing technologies for fabricating haptic actuators is provided. In particular, the focus is on the challenges and potential solutions associated with integration of multi-material actuators, with an eye toward improving the fidelity and robustness of the printing process. Then the progress in achieving compact, lightweight haptic actuators by using an open-source extrusion printer to integrate different polymers and composites in freeform designs is reported. Two haptic interfaces-a tactile surface and a kinesthetic glove-are demonstrated to show that printing with organic materials is a versatile approach for rapid prototyping of various types of haptic devices.

Three-dimensional surface printing method for interconnecting electrodes on opposite sides of substrates.

As the application of the direct printing method becomes diversified, printing on substrates with non-flat surfaces is increasingly required. However, printing on three-dimensional surfaces suffers from a number of difficulties, which include ink flow due to gravity, and the connection of print lines over sharp edges. This study presents an effective way to print a fine pattern (~ 30 µm) on three different faces with sharp edge boundaries. The method uses a deflectable and stretchable jet stream of conductive ink, which is produced by near-field electrospinning (NFES) technique. Due to added polymer in the ink, the jet stream from the nozzle is less likely to be disconnected, even when it is deposited over sharp edges of objects. As a practical industrial application, we demonstrate that the method can be effectively used for recent display applications, which require the connection of electrical signal and power on both sides of the glass. When the total length of printed lines along the 'Π' shaped glass surfaces was 1.2 mm, we could achieve the average resistance of 0.84 Ω.

How to manipulate droplet jetting from needle type jet dispensers.

The needle-type inkjet dispenser has been widely used for various research and industrial purposes. The droplet jetting from the dispenser is closely related to the needle motion, which strikes against the nozzle seat. The strike of the needle on the nozzle seat often cause additional impact due to the bounce back, which may produce multiple droplets per jetting trigger. However, the needle motion is difficult to measure, and the actual behaviors have been known little. In this study, we measured the needle motion using an accelerometer and visualized jetting images to understand jetting behavior in relation to the needle motion. Then, we investigated various parameter effects on needle motion and jetting behaviors based on our proposed measurement methods. From the experimental results, we found that needle travel distance should be in the optimal range in order to produce single droplet per jetting trigger. In conclusion, we proposed an effective parameter selection method for the optimal jetting based on understanding of the jetting physics.

High-resolution Patterning Using Two Modes of Electrohydrodynamic Jet: Drop on Demand and Near-field Electrospinning.

Electrohydrodynamic (EHD) jet printing has drawn attention in various fields because it can be used as a high-resolution and low-cost direct patterning tool. EHD printing uses a fluidic supplier to maintain the extruded meniscus by pushing the ink out of the nozzle tip. The electric field is then used to pull the meniscus down to the substrate to produce high-resolution patterns. Two modes of EHD printing have been used for fine patterning: continuous near-field electrospinning (NFES) and dot-based drop-on-demand (DOD) EHD printing. According to the printing modes, the requirements for the printing equipment and ink viscosity will differ. Even though two different modes can be implemented with a single EHD printer, the realization methods significantly differ in terms of ink, fluidic system, and driving voltage. Consequently, without a proper understanding of the jetting requirements and limitations, it is difficult to obtain the desired results. The purpose of this paper is to present a guideline so that inexperienced researchers can reduce the trial and error efforts to use the EHD jet for their specific research and development purposes. To demonstrate the fine-patterning implementation, we use Ag nanoparticle ink for the conductive patterning in the protocol. In addition, we also present the generalized printing guidelines that can be used for other types of ink for various fine-patterning applications.

Measurement of inkjet first-drop behavior using a high-speed camera.

Drop-on-demand inkjet printing has been used as a manufacturing tool for printed electronics, and it has several advantages since a droplet of an exact amount can be deposited on an exact location. Such technology requires positioning the inkjet head on the printing location without jetting, so a jetting pause (non-jetting) idle time is required. Nevertheless, the behavior of the first few drops after the non-jetting pause time is well known to be possibly different from that which occurs in the steady state. The abnormal behavior of the first few drops may result in serious problems regarding printing quality. Therefore, a proper evaluation of a first-droplet failure has become important for the inkjet industry. To this end, in this study, we propose the use of a high-speed camera to evaluate first-drop dissimilarity. For this purpose, the image acquisition frame rate was determined to be an integer multiple of the jetting frequency, and in this manner, we can directly compare the droplet locations of each drop in order to characterize the first-drop behavior. Finally, we evaluate the effect of a sub-driving voltage during the non-jetting pause time to effectively suppress the first-drop dissimilarity.

A fully roll-to-roll gravure-printed carbon nanotube-based active matrix for multi-touch sensors.

Roll-to-roll (R2R) printing has been pursued as a commercially viable high-throughput technology to manufacture flexible, disposable, and inexpensive printed electronic devices. However, in recent years, pessimism has prevailed because of the barriers faced when attempting to fabricate and integrate thin film transistors (TFTs) using an R2R printing method. In this paper, we report 20 × 20 active matrices (AMs) based on single-walled carbon nanotubes (SWCNTs) with a resolution of 9.3 points per inch (ppi) resolution, obtained using a fully R2R gravure printing process. By using SWCNTs as the semiconducting layer and poly(ethylene terephthalate) (PET) as the substrate, we have obtained a device yield above 98%, and extracted the key scalability factors required for a feasible R2R gravure manufacturing process. Multi-touch sensor arrays were achieved by laminating a pressure sensitive rubber onto the SWCNT-TFT AM. This R2R gravure printing system overcomes the barriers associated with the registration accuracy of printing each layer and the variation of the threshold voltage (Vth). By overcoming these barriers, the R2R gravure printing method can be viable as an advanced manufacturing technology, thus enabling the high-throughput production of flexible, disposable, and human-interactive cutting-edge electronic devices based on SWCNT-TFT AMs.

An inkjet vision measurement technique for high-frequency jetting.

Inkjet technology has been used as manufacturing a tool for printed electronics. To increase the productivity, the jetting frequency needs to be increased. When using high-frequency jetting, the printed pattern quality could be non-uniform since the jetting performance characteristics including the jetting speed and droplet volume could vary significantly with increases in jet frequency. Therefore, high-frequency jetting behavior must be evaluated properly for improvement. However, it is difficult to measure high-frequency jetting behavior using previous vision analysis methods, because subsequent droplets are close or even merged. In this paper, we present vision measurement techniques to evaluate the drop formation of high-frequency jetting. The proposed method is based on tracking target droplets such that subsequent droplets can be excluded in the image analysis by focusing on the target droplet. Finally, a frequency sweeping method for jetting speed and droplet volume is presented to understand the overall jetting frequency effects on jetting performance.