Manufacturing of three-dimensionally microstructured nanocomposites through microfluidic infiltration

Area of Science:

• Materials Science
• Nanotechnology
• Microengineering

Background:

• Advanced composite materials require precise structural control at the microscale.
• Fabricating complex three-dimensional (3D) microstructures with integrated functionalities remains a challenge.

Purpose of the Study:

• To develop a novel method for fabricating microstructured composite beams reinforced with 3D patterned nanocomposite microfilaments.
• To demonstrate the potential of this technique for creating functional macroscopic products for microengineering.

Main Methods:

• Fabrication of 3D microfluidic networks using layer-by-layer deposition of fugitive ink filaments, resin casting, and ink removal.
• Preparation of nanocomposite suspensions with nanofillers (e.g., single-walled carbon nanotubes) dispersed in polymer matrices.
• Infiltration of the microfluidic networks with nanocomposite suspensions using a pressure gradient, followed by UV/heat curing to solidify the structure.

Main Results:

• Successfully fabricated self-supported 3D microstructured composite beams with complex internal geometries.
• Demonstrated the infiltration of tubular microfluidic networks with thermosetting nanocomposites.
• Achieved solidified 3D-reinforced composite structures with potential for microengineering applications.

Conclusions:

• The presented technique enables the creation of intricate, 3D-patterned nanocomposite microstructures.
• This method offers a pathway for designing and manufacturing functional nanocomposite macroscopic products.
• The fabricated beams are suitable for microengineering applications, including actuators and sensors.