Structured multimaterial filaments for 3D printing of optoelectronics

Area of Science:

• Materials Science
• Additive Manufacturing
• Nanotechnology

Background:

• Simultaneous 3D printing of diverse materials like metals, polymers, and semiconductors with high resolution and device-quality interfaces is a significant challenge.
• Precise spatial arrangement of materials for optimal device performance and electrical connectivity is difficult with current high-speed 3D printing methods.

Purpose of the Study:

• To develop a novel 3D printing approach for fabricating complex, multi-material functional devices.
• To overcome limitations in material integration and interface quality in additive manufacturing.

Main Methods:

• Development of structured multi-material filaments incorporating disparate materials (metals, polymers, semiconductors).
• Utilization of an external adhesion promoter to enhance interfacial bonding and topological control during printing.
• Printing of filaments into complex 3D structures, including serpentine and spherical sensors, and hierarchical objects with electroluminescent pixels.

Main Results:

• Achieved device-quality interfaces and high-resolution printing (55 µm) for multi-material 3D structures.
• Successfully fabricated fully-connected 3D light sensors capable of micron-scale spatial resolution.
• Created 3D objects with integrated electroluminescent pixels using metallic microspheres, overcoming surface tension limitations.

Conclusions:

• The developed structured multi-material filaments and printing strategy enable the creation of custom 3D functional devices with unprecedented complexity and performance.
• This approach overcomes existing barriers in multi-material 3D printing, paving the way for novel device architectures.
• The technology facilitates the fabrication of devices not achievable with current additive manufacturing techniques.