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Reactive Laser Additive Manufacturing of Hierarchically Structured Aerogels.

Shuichiro Hayashi^1,2, Ankit Das^1,2, Marco Rupp^1,2

¹Princeton Materials Institute, Princeton University, Princeton, New Jersey, USA.

Advanced Materials (Deerfield Beach, Fla.)

|May 9, 2026

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This summary is machine-generated.

Researchers developed reactive laser additive manufacturing (AM) to create advanced materials. This method uses special powders to synthesize materials during printing, enhancing energy storage performance.

Area of Science:

Materials Science
Chemical Engineering
Additive Manufacturing

Background:

Additive manufacturing (AM) is crucial for energy materials but often limited to passive precursor shaping.
Sustainable and scalable manufacturing demands innovative AM techniques.

Purpose of the Study:

To introduce reactive laser AM, enabling materials synthesis during the printing process.
To demonstrate the creation of hierarchically structured graphitic aerogels via in situ chemical reactions.

Main Methods:

Incorporating eutectic alkali halide salts into protein-based powders for reactive AM.
Utilizing localized laser heating to drive vapor-phase chemistry and in situ growth.
Designing precursor composition to activate chemical reactions during printing.

Keywords:

additive manufacturing energy storage graphitic aerogels laser materials processing vapor‐liquid‐solid growth

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Main Results:

Rapid, single-step formation of graphitic aerogel monoliths with multilevel hierarchical architecture.
Achieved macroporous frameworks decorated with microtubular arrays and nanoscale features.
Demonstrated a tenfold enhancement in gravimetric capacitance (∼162 F g^-1) for energy storage electrodes.

Conclusions:

Reactive laser AM reframes AM as a dynamic platform for reaction-driven materials-by-design.
Engineered reactivity through feedstock design enables efficient synthesis of complex materials.
This approach offers a scalable pathway for advanced energy materials manufacturing.