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Micro diamond tools are indispensable for the efficient machining of microstructured surfaces. The precision in tool manufacturing and cutting performance directly determines the processing quality of components. The manufacturing of high-quality micro diamond tools relies on scientific design methods and appropriate processing techniques. However, there is currently a lack of systematic review on the design and manufacturing methods of micro diamond tools in academia. This study systematically summarizes and analyzes modern manufacturing methods for micro diamond tools, as well as the impact of tool waviness, sharpness, and durability on machining quality. Subsequently, a design method is proposed based on the theory of cutting edge strength distribution to enhance tool waviness, sharpness, and durability. Finally, this paper presents current technical challenges faced by micro diamond tools along with potential future solutions to guide scientists in this field. The aim of this review is to contribute to the further development of the current design and manufacturing processes for micro diamond cutting tools.

High-bandwidth nano-positioning stages (NPSs) have boosted the advancement of modern ultra-precise, ultra-fast measurement and manufacturing technologies owing to their fast dynamic response, high stiffness and nanoscale resolution. However, the nonlinear actuation, lightly damped resonance and multi-axis cross-coupling effect bring significant challenges to the design, modeling and control of high-bandwidth NPSs. Consequently, numerous advanced works have been reported over the past decades to address these challenges. Here, this article provides a comprehensive review of high-bandwidth NPSs, which covers four representative aspects including mechanical design, system modeling, parameters optimization and high-bandwidth motion control. Besides, representative high-bandwidth NPSs applied to atomic force microscope and fast tool servo are highlighted. By providing an extensive overview of the design procedure for high-bandwidth NPSs, this review aims to offer a systemic solution for achieving operation with high speed, high accuracy and high resolution. Furthermore, remaining difficulties along with future developments in this fields are concluded and discussed.

Micro/nanorobots (MNRs) capable of performing tasks at the micro- and nanoscale hold great promise for applications in cutting-edge fields such as biomedical engineering, environmental engineering, and microfabrication. To cope with the intricate and dynamic environments encountered in practical applications, the development of high performance MNRs is crucial. They have evolved from single-material, single-function, and simple structure to multi-material, multi-function, and complex structure. However, the design and manufacturing of high performance MNRs with complex multi-material three-dimensional structures at the micro- and nanoscale pose significant challenges that cannot be addressed by conventional serial design strategies and single-process manufacturing methods. The material-interface-structure-function/ performance coupled design methods and the additive/formative/subtractive composite manufacturing methods offer the opportunity to design and manufacture MNRs with multi-materials and complex structures under multi-factor coupling, thus paving the way for the development of high performance MNRs. In this paper, we take the three core capabilities of MNRs—mobility, controllability, and load capability—as the focal point, emphasizing the coupled design methods oriented towards their function/performance and the composite manufacturing methods for their functional structures. The limitations of current investigation are also discussed, and our envisioned future directions for design and manufacture of MNRs are shared. We hope that this review will provide a framework template for the design and manufacture of high performance MNRs, serving as a roadmap for researchers interested in this area.

Significant advancements in ultra-precision machining technology have forced a re-examination of the spindle perpendicularity errors’ impact on the milled surface quality at the micro-nano scale. In this paper, a method of spindle precision adjustment is proposed to enhance surface finish quality. Sensitive errors in the machining process are identified using multi-body kinematic theory, with the milling process serving as an example. A two-degree-of-freedom (2-DOF) rotation platform is designed, optimized, and fabricated. The platform’s static model is established based on elastic beam theory and verified by finite element analysis. Structural parameters are optimized via the response surface method in combination with the Pareto front. Experimental results reveal the effects of spindle speed, voltage amplitude, vibration frequency, cutting depth, and feed rate on the platform’s modulation performance. The static modulation experiment shows that the perpendicularity error between the spindle and the guideway can be reduced from 92.5 μ rad to 0.25 μ rad. Finally, milling experiments show that the surface quality can be improved by 37.6% after spindle modulation.

Soft (flexible and stretchable) biosensors have great potential in real-time and continuous health monitoring of various physiological factors, mainly due to their better conformability to soft human tissues and organs, which maximizes data fidelity and minimizes biological interference. Most of the early soft sensors focused on sensing physical signals. Recently, it is becoming a trend that novel soft sensors are developed to sense and monitor biochemical signals in situ in real biological environments, thus providing much more meaningful data for studying fundamental biology and diagnosing diverse health conditions. This is essential to decentralize the healthcare resources towards predictive medicine and better disease management. To meet the requirements of mechanical softness and complex biosensing, unconventional materials, and manufacturing process are demanded in developing biosensors. In this review, we summarize the fundamental approaches and the latest and representative design and fabrication to engineer soft electronics (flexible and stretchable) for wearable and implantable biochemical sensing. We will review the rational design and ingenious integration of stretchable materials, structures, and signal transducers in different application scenarios to fabricate high-performance soft biosensors. Focus is also given to how these novel biosensors can be integrated into diverse important physiological environments and scenarios in situ , such as sweat analysis, wound monitoring, and neurochemical sensing. We also rethink and discuss the current limitations, challenges, and prospects of soft biosensors. This review holds significant importance for researchers and engineers, as it assists in comprehending the overarching trends and pivotal issues within the realm of designing and manufacturing soft electronics for biochemical sensing.

On-machine inspection has a significant impact on improving high-precision and efficient machining of sculptured surfaces. Due to the lack of machining information and the inability to adapt the parameters to the dynamic cutting conditions, theoretical modeling of profile inspection usually leads to insufficient adaptation, which causes inaccuracy problems. To address the above issues, a novel coupled model for profile inspection is proposed by combining the theoretical model and the data-driven model. The key process is to first realize local feature extraction based on the acquired vibration signals. The hybrid sampling model, which fuses geometric feature terms and vibration feature terms, is modeled by the lever principle. Then, the weight of each feature term is adaptively assigned by a multi-objective multi-verse optimizer. Finally, an inspection error compensation model based on the attention mechanism considering different probe postures is proposed to reduce the impact of pre-travel and radius errors on inspection accuracy. The anisotropy of the probe system error and its influence mechanism on the inspection accuracy are analyzed quantitatively and qualitatively. Compared with the previous models, the proposed hybrid profile inspection model can significantly improve the accuracy and efficiency of on-machine sampling. The proposed compensation model is able to correct the inspection errors with better accuracy. Simulations and experiments demonstrate the feasibility and validity of the proposed methods. The proposed model and corresponding new findings contribute to high-precision and efficient on-machine inspection, and help to understand the coupling mechanism of inspection errors.

Integration of sensors with engineering thermoplastics allows to track their health and surrounding stimuli. As one of vital backbones to construct sensor systems, copper (Cu) is highly conductive and cost-effective, yet tends to easily oxidize during and after processing. Herein, an in-situ integrated sensor system on engineering thermoplastics via hybrid laser direct writing is proposed, which primarily consists of laser-passivated functional Cu interconnects and laser-induced carbon-based sensors. Through a one-step photothermal treatment, the resulting functional Cu interconnects after reductive sintering and passivation are capable of resisting long-term oxidation failure at high temperatures (up to 170 °C) without additional encapsulations. Interfacing with signal processing units, such an all-in-one system is applied for long-term and real-time temperature monitoring. This integrated sensor system with facile laser manufacturing strategies holds potentials for health monitoring and fault diagnosis of advanced equipment such as aircrafts, automobiles, high-speed trains, and medical devices.

Real-time physiological information monitoring can predict and prevent disease, or improve treatment by early diagnosis. A comprehensive and continuous monitoring of human health requires highly integrated wearable and comfortable sensing devices. To address this need, we propose a low-cost electronic fabric-enabled multifunctional flexible sensing integration platform that includes a flexible pressure sensor for monitoring postural pressure, a humidity sensor for monitoring the humidity of the skin surface, and a flexible temperature sensor for visualizing the ambient temperature around the human body. Thanks to the unique rough surface texture, hierarchical structure, and robust electromechanical features of the MXene-modified nonwoven fabrics, the flexible pressure sensor can achieve a monitoring sensitivity of 1529.1 kPa ^−1 and a pressure range of 150 kPa, which meets the demand for human pressure detection. In addition, the unique porous structure of the fabric and the stacked multilayer structure of MXene enable the humidity sensor to exhibit extremely high monitoring sensitivity, even through clothing, and still be able to detect the humidity on the skin surface. Temperature sensors based on screen-printed thermochromic liquid crystals enable visual monitoring in the range of 0 °C–65 °C. Through further integration with flexible printed circuit board circuits, we demonstrate a proof-of-concept device that enables real-time monitoring of human physiological information such as physical pressure, humidity, and ambient temperature environment, suggesting that the device provides an excellent platform for the development of commercially viable wearable healthcare monitors.

Sub-wavelength nanostructure lattices provide versatile platforms for light control and the basis for various novel phenomena and applications in physics, material science, chemistry, biology, and energy. The thriving study of nanostructure lattices is building on the remarkable progress of nanofabrication techniques, especially for the possibility of fabricating larger-area patterns while achieving higher-quality lattices, complex shapes, and hybrid materials units. In this review, we present a comprehensive review of techniques for large-area fabrication of optical nanostructure arrays, encompassing direct writing, self-assembly, controllable deposition, and nanoimprint/print methods. Furthermore, a particular focus is made on the recent improvement of unit accuracy and diversity, leading to integrated and multifunctional structures for devices and applications.

High-temperature thin-film thermocouples (TFTCs) have attracted significant attention in the aerospace and steel metallurgy industry. However, previous studies on TFTCs have primarily focused on the two-dimensional planar-type, whose thermal sensitive area has to be perpendicular to the test environment, and therefore affects the thermal fluids pattern or loses accuracy. In order to address this problem, recent studies have developed three-dimensional probe-type TFTCs, which can be set parallel to the test environment. Nevertheless, the probe-type TFTCs are limited by their measurement threshold and poor stability at high temperatures. To address these issues, in this study, we propose a novel probe-type TFTC with a sandwich structure. The sensitive layer is compounded with indium oxide doped zinc oxide and fabricated using screen-printing technology. With the protection of sandwich structure on electrode film, the sensor demonstrates robust high-temperature stability, enabling continuous working at 1200 °C above 5 h with a low drift rate of 2.3 °C·h ^−1 . This sensor exhibits a high repeatability of 99.3% when measuring a wide range of temperatures, which is beyond the most existing probe-type TFTCs reported in the literature. With its excellent high-temperature performance, this temperature sensor holds immense potentials for enhancing equipment safety in the aerospace engineering and ensuring product quality in the steel metallurgy industry.

Multi-material 3D fabrication at the nanoscale has been a long-sought goal in additive manufacturing, with great potential for the direct construction of functional micro/nanosystems rather than just arbitrary 3D structures. To achieve this goal, researchers have introduced several nanoscale 3D printing principles, explored various multi-material switching and combination strategies, and demonstrated their potential applications in 3D integrated circuits, optoelectronics, biological devices, micro/nanorobots, etc. Although some progress has been made, it is still at the primary stage, and a serious breakthrough is needed to directly construct functional micro/nano systems. In this perspective, the development, current status and prospects of multi-material 3D nanoprinting are presented. We envision that this 3D printing will unlock innovative solutions and make significant contributions to various technologies and industries in the near future.

Because of their high safety, low cost, and high volumetric specific capacity, zinc-ion batteries (ZIBs) are considered promising next-generation energy storage devices, especially given their high potential for large-scale energy storage. Despite these advantages, many problems remain for ZIBs—such as Zn dendrite growth, hydrogen evolution, and Zn anode corrosion—which significantly reduce the coulomb efficiency and reversibility of the battery and limit its cycle lifespan, resulting in much uncertainty in terms of its practical applications. Numerous electrolyte additives have been proposed in recent years to solve the aforementioned problems. This review focuses on electrolyte additives and discusses the different substances employed as additives to overcome the problems by altering the Zn ^2+ solvation structure, creating a protective layer at the anode–electrolyte interface, and modulating the Zn ^2+ distribution to be even and Zn deposition to be uniform. On the basis of the review, the possible research strategies, future directions of electrolyte additive development, and the existing problems to be solved are also described.

Triboelectric nanogenerators (TENGs) stand at the forefront of energy harvesting innovation, transforming mechanical energy into electrical power through triboelectrification and electrostatic induction. This groundbreaking technology addresses the urgent need for sustainable and renewable energy solutions, opening new avenues for self-powered systems. Despite their potential, TENGs face challenges such as material optimization for enhanced triboelectric effects, scalability, and improving conversion efficiency under varied conditions. Durability and environmental stability also pose significant hurdles, necessitating further research towards more resilient systems. Nature inspired TENG designs offer promising solutions by emulating biological processes and structures, such as the energy mechanisms of plants and the textured surfaces of animal skins. This biomimetic approach has led to notable improvements in material properties, structural designs, and overall TENG performance, including enhanced energy conversion efficiency and environmental robustness. The exploration into bio-inspired TENGs has unlocked new possibilities in energy harvesting, self-powered sensing, and wearable electronics, emphasizing reduced energy consumption and increased efficiency through innovative design. This review encapsulates the challenges and advancements in nature inspired TENGs, highlighting the integration of biomimetic principles to overcome current limitations. By focusing on augmented electrical properties, biodegradability, and self-healing capabilities, nature inspired TENGs pave the way for more sustainable and versatile energy solutions.

Traditional methods such as mechanical testing and x-ray computed tomography (CT), for quality assessment in laser powder-bed fusion (LPBF), a class of additive manufacturing (AM), are resource-intensive and conducted post-production. Recent advancements in in-situ monitoring, particularly using optical tomography (OT) to detect near-infrared light emissions during the process, offer an opportunity for in-situ defect detection. However, interpreting OT datasets remains challenging due to inherent process characteristics and disturbances that may obscure defect identification. This paper introduces a novel machine learning-based approach that integrates a self-organizing map, a fuzzy logic scheme, and a tailored U-Net architecture to enhance defect prediction capabilities during the LPBF process. This model not only predicts common flaws such as lack of fusion and keyhole defects through analysis of in-situ OT data, but also allows quality assurance professionals to apply their expert knowledge through customizable fuzzy rules. This capability facilitates a more nuanced and interpretable model, enhancing the likelihood of accurate defect detection. The efficacy of this system has been validated through experimental analyses across various process parameters, with results validated by subsequent CT scans, exhibiting strong performance with average model scores ranging from 0.375 to 0.819 for lack of fusion defects and from 0.391 to 0.616 for intentional keyhole defects. These findings underscore the model’s reliability and adaptability in predicting defects, highlighting its potential as a transformative tool for in-process quality assurance in AM. A notable benefit of this method is its adaptability, allowing the end-user to adjust the probability threshold for defect detection based on desired quality requirements and custom fuzzy rules.

Piezoelectric ultrasonic transducers have shown great potential in biomedical applications due to their high acoustic-to-electric conversion efficiency and large power capacity. The focusing technique enables the transducer to produce an extremely narrow beam, greatly improving the resolution and sensitivity. In this work, we summarize the fundamental properties and biological effects of the ultrasound field, aiming to establish a correlation between device design and application. Focusing techniques for piezoelectric transducers are highlighted, including material selection and fabrication methods, which determine the final performance of piezoelectric transducers. Numerous examples, from ultrasound imaging, neuromodulation, tumor ablation to ultrasonic wireless energy transfer, are summarized to highlight the great promise of biomedical applications. Finally, the challenges and opportunities of focused ultrasound transducers are presented. The aim of this review is to bridge the gap between focused ultrasound systems and biomedical applications.

Soft robot incarnates its unique advantages in deep-sea exploration, but grapples with high hydrostatic pressure’s unpredictable impact on its mechanical performances. In our previous work, a self-powered soft robot showed excellent work performance in the Mariana Trench at a depth of 11 000 m, yet experienced notable degradation in deforming capability. Here, we propose a magnetic loading method for characterizing elastomer’s mechanical properties under extremely high hydrostatic pressure of up to 120 MPa. This method facilitates remote loading and enables in-situ observation, so that the dimensions and deformation at high hydrostatic pressure are obtained and used for calculations. The results reveal that the Young’s modulus of Polydimethylsiloxane (PDMS) monotonously increases with pressure. It is found that the relative increase in Young’s modulus is determined by its initial value, which is 8% for an initial Young’s modulus of 2200 kPa and 38% for 660 kPa. The relation between initial Young’s modulus and relevant increase can be fitted by an exponential function. The bulk modulus of PDMS is about 1.4 GPa at 20 °C and is barely affected by hydrostatic pressure. The method can quantify alterations in the mechanical properties of elastomers induced by hydrostatic pressure, and provide guidance for the design of soft robots which serve in extreme pressure environment.

Triboelectric nanogenerators (TENG), renowned for their remarkable capability to harness weak mechanical energy from the environment, have gained considerable attention owing to their cost-effectiveness, high output, and adaptability. This review provides a unique perspective by conducting a comprehensive and in-depth analysis of magnetically assisted TENGs that encompass structures, materials, and self-powered sensing systems. We systematically summarize the diverse functions of the magnetic assistance for TENGs, including system stiffness, components of the hybrid electromagnetic-triboelectric generator, transmission, and interaction forces. In the material domain, we review the incorporation of magnetic nano-composites materials, along with ferrofluid-based TENG and microstructure verification, which have also been summarized based on existing research. Furthermore, we delve into the research progress on physical quantity sensing and human-machine interface in magnetic-assisted TENGs. Our analysis highlights that magnetic assistance extends beyond the repulsive and suction forces under a magnetic field, thereby playing multifaceted roles in improving the output performance and environmental adaptability of the TENGs. Finally, we present the prevailing challenges and offer insights into the future trajectory of the magnetic-assisted TENGs development.

The continuous evolution of chip manufacturing demands the development of materials with ultra-low dielectric constants. With advantageous dielectric and mechanical properties, initiated chemical vapor deposited (iCVD) poly(1,3,5-trimethyl-1,3,5-trivinyl cyclotrisiloxane) (pV _3 D _3 ) emerges as a promising candidate. However, previous works have not explored etching for this cyclosiloxane polymer thin film, which is indispensable for potential applications to the back-end-of-line fabrication. Here, we developed an etching process utilizing O _2 /Ar remote plasma for cyclic removal of iCVD pV _3 D _3 thin film at sub-nanometer scale. We employed in-situ quartz crystal microbalance to investigate the process parameters including the plasma power, plasma duration and O _2 flow rate. X-ray photoelectron spectroscopy and cross-sectional microscopy reveal the formation of an oxidized skin layer during the etching process. This skin layer further substantiates an etching mechanism driven by surface oxidation and sputtering. Additionally, this oxidized skin layer leads to improved elastic modulus and hardness and acts as a barrier layer for protecting the bottom cyclosiloxane polymer from further oxidation.

Droplet transport still faces numerous challenges, such as a limited transport distance, large volume loss, and liquid contamination. Inspired by the principle of ‘synergistic biomimetics’, we propose a design for a platform that enables droplets to be self-propelled. The orchid leaf-like three-dimensional driving structure provides driving forces for the liquid droplets, whereas the lotus leaf-like superhydrophobic surface prevents liquid adhesion, and the bamboo-like nodes enable long-distance transport. During droplet transport, no external energy input is required, no fluid adhesion or residue is induced, and no contamination or mass loss of the fluid is caused. We explore the influence of various types and parameters of wedge structures on droplet transportation, the deceleration of droplet speed at nodal points, and the distribution of internal pressure. The results indicate that the transport platform exhibits insensitivity to pH value and temperature. It allows droplets to be transported with varying curvatures in a spatial environment, making it applicable in tasks like target collection, as well as load, fused, anti-gravity, and long-distance transport. The maximum droplet transport speed reached (58 ± 5) mm·s ^−1 , whereas the transport distance extended to (136 ± 4) mm. The developed platform holds significant application prospects in the fields of biomedicine and chemistry, such as high-throughput screening of drugs, genomic bioanalysis, microfluidic chip technology for drug delivery, and analysis of biological samples.

At present, the research on ferroelectric photovoltaic materials mainly focuses on photoelectric detection. In the context of the rapid development of the Internet of Things (IoT), it is particularly important to use smaller thin-film devices as sensors. In this work, an indium tin oxide/bismuth ferrite (BFO)/lanthanum nickelate device has been fabricated on an F-doped tin oxide glass substrate using the sol–gel method. The sensor can continuously output photoelectric signals with little environmental impact. Compared to other types of sensors, this photoelectric sensor has an ultra-low response time of 1.25 ms and ultra-high sensitivity. Furthermore, a material recognition system based on a BFO sensor is developed. It can effectively identify eight kinds of materials that are difficult for human eyes to distinguish. This provides new ideas and methods for developing the IoT in material identification.

The emergence of the internet of things has promoted wireless communication’s evolution towards multi-band and multi-area utilization. Notably, forthcoming sixth-generation (6G) communication standards, incorporating terahertz (THz) frequencies alongside existing gigahertz (GHz) modes, drive the need for a versatile multi-band electromagnetic wave (EMW) absorbing and shielding material. This study introduces a pivotal advance via a new strategy, called ultrafast laser-induced thermal-chemical transformation and encapsulation of nanoalloys (LITENs). Employing multivariate metal-organic frameworks, this approach tailors a porous, multifunctional graphene-encased magnetic nanoalloy (GEMN). By fine-tuning pulse laser parameters and material components, the resulting GEMN excels in low-frequency absorption and THz shielding. GEMN achieves a breakthrough of minimum reflection loss of −50.6 dB in the optimal C-band (around 4.98 GHz). Computational evidence reinforces GEMN’s efficacy in reducing radar cross sections. Additionally, GEMN demonstrates superior electromagnetic interference shielding, reaching 98.92 dB under THz band (0.1–2 THz), with the mean value result of 55.47 dB. These accomplishments underscore GEMN’s potential for 6G signal shielding. In summary, LITEN yields the remarkable EMW controlling performance, holding promise in both GHz and THz frequency domains. This contribution heralds a paradigm shift in EM absorption and shielding materials, establishing a universally applicable framework with profound implications for future pursuits.

The rotator cuff tear has emerged as a significant global health concern. However, existing therapies fail to fully restore the intricate bone-to-tendon gradients, resulting in compromised biomechanical functionalities of the reconstructed enthesis tissues. Herein, a tri-layered core–shell microfibrous scaffold with layer-specific growth factors (GFs) release is developed using coaxial electrohydrodynamic (EHD) printing for in situ cell recruitment and differentiation to facilitate gradient enthesis tissue repair. Stromal cell-derived factor-1 (SDF-1) is loaded in the shell, while basic fibroblast GF, transforming GF-beta, and bone morphogenetic protein-2 are loaded in the core of the EHD-printed microfibrous scaffolds in a layer-specific manner. Correspondingly, the tri-layered microfibrous scaffolds have a core–shell fiber size of (25.7 ± 5.1) μ m, with a pore size sequentially increasing from (81.5 ± 4.6) μ m to (173.3 ± 6.9) μ m, and to (388.9 ± 6.9 μ m) for the tenogenic, chondrogenic, and osteogenic instructive layers. A rapid release of embedded GFs is observed within the first 2 d, followed by a faster release of SDF-1 and a slightly slower release of differentiation GFs for approximately four weeks. The coaxial EHD-printed microfibrous scaffolds significantly promote stem cell recruitment and direct their differentiation toward tenocyte, chondrocyte, and osteocyte phenotypes in vitro . When implanted in vivo , the tri-layered core–shell microfibrous scaffolds rapidly restored the biomechanical functions and promoted enthesis tissue regeneration with native-like bone-to-tendon gradients. Our findings suggest that the microfibrous scaffolds with layer-specific GFs release may offer a promising clinical solution for enthesis regeneration.

Exsolution, as an effective approach to constructing particle-decorated interfaces, is still challenging to yield interfacial films rather than isolated particles. Inspired by in vivo near-infrared laser photothermal therapy, using 3 mol% Y _2 O _3 stabilized tetragonal zirconia polycrystals (3Y-TZP) as host oxide matrix and iron-oxide (Fe _3 O _4 / γ -Fe _2 O _3 / α -Fe _2 O _3 ) materials as photothermal modulator and exsolution resource, femtosecond laser ultrafast exsolution approach is presented enabling to conquer this challenge. The key is to trigger photothermal annealing behavior via femtosecond laser ablation to initialize phase transition from monoclinic zirconia (m-ZrO _2 ) to tetragonal zirconia (t-ZrO _2 ) and induce t-ZrO _2 columnar crystal growth. Fe-ions rapidly segregate along grain boundaries and diffuse towards the outmost surface, and become ‘frozen’, highlighting the potential to use photothermal materials and ultrafast heating/quenching behaviors of femtosecond laser ablation for interfacial exsolution. Triggering interfacial iron-oxide coloring exsolution is composition and concentration dependent. Photothermal materials themselves and corresponding photothermal transition capacity play a crucial role, initializing at 2 wt%, 3 wt%, and 5 wt% for Fe _3 O _4 / γ -Fe _2 O _3 / α -Fe _2 O _3 doped 3Y-TZP samples. Due to different photothermal effects, exsolution states of ablated 5 wt% Fe _3 O _4 / γ -Fe _2 O _3 / α -Fe _2 O _3 -doped 3Y-TZP samples are totally different, with whole coverage, exhaustion (ablated away) and partial exsolution (rich in the grain boundaries in subsurface), respectively. Femtosecond laser ultrafast photothermal exsolution is uniquely featured by up to now the deepest microscale (10 μ m from 5 wt%-Fe _3 O _4 -3Y-TZP sample) Fe-elemental deficient layer for exsolution and the whole coverage of exsolved materials rather than the formation of isolated exsolved particles by other methods. It is believed that this novel exsolution method may pave a good way to modulate interfacial properties for extensive applications in the fields of biology, optics/photonics, energy, catalysis, environment, etc.

Driven by the growing demand for next-generation displays, the development of advanced luminescent materials with exceptional photoelectric properties is rapidly accelerating, with such materials including quantum dots and phosphors, etc. Nevertheless, the primary challenge preventing the practical application of these luminescent materials lies in meeting the required durability standards. Atomic layer deposition (ALD) has, therefore, been employed to stabilize luminescent materials, and as a result, flexible display devices have been fabricated through material modification, surface and interface engineering, encapsulation, cross-scale manufacturing, and simulations. In addition, the appropriate equipment has been developed for both spatial ALD and fluidized ALD to satisfy the low-cost, high-efficiency, and high-reliability manufacturing requirements. This strategic approach establishes the groundwork for the development of ultra-stable luminescent materials, highly efficient light-emitting diodes (LEDs), and thin-film packaging. Ultimately, this significantly enhances their potential applicability in LED illumination and backlighted displays, marking a notable advancement in the display industry.

Metal additive manufacturing (AM) has been extensively studied in recent decades. Despite the significant progress achieved in manufacturing complex shapes and structures, challenges such as severe cracking when using existing alloys for laser powder bed fusion (L-PBF) AM have persisted. These challenges arise because commercial alloys are primarily designed for conventional casting or forging processes, overlooking the fast cooling rates, steep temperature gradients and multiple thermal cycles of L-PBF. To address this, there is an urgent need to develop novel alloys specifically tailored for L-PBF technologies. This review provides a comprehensive summary of the strategies employed in alloy design for L-PBF. It aims to guide future research on designing novel alloys dedicated to L-PBF instead of adapting existing alloys. The review begins by discussing the features of the L-PBF processes, focusing on rapid solidification and intrinsic heat treatment. Next, the printability of the four main existing alloys (Fe-, Ni-, Al- and Ti-based alloys) is critically assessed, with a comparison of their conventional weldability. It was found that the weldability criteria are not always applicable in estimating printability. Furthermore, the review presents recent advances in alloy development and associated strategies, categorizing them into crack mitigation-oriented, microstructure manipulation-oriented and machine learning-assisted approaches. Lastly, an outlook and suggestions are given to highlight the issues that need to be addressed in future work.

Recent advances in functionally graded additive manufacturing (FGAM) technology have enabled the seamless hybridization of multiple functionalities in a single structure. Soft robotics can become one of the largest beneficiaries of these advances, through the design of a facile four-dimensional (4D) FGAM process that can grant an intelligent stimuli-responsive mechanical functionality to the printed objects. Herein, we present a simple binder jetting approach for the 4D printing of functionally graded porous multi-materials (FGMM) by introducing rationally designed graded multiphase feeder beds. Compositionally graded cross-linking agents gradually form stable porous network structures within aqueous polymer particles, enabling programmable hygroscopic deformation without complex mechanical designs. Furthermore, a systematic bed design incorporating additional functional agents enables a multi-stimuli-responsive and untethered soft robot with stark stimulus selectivity. The biodegradability of the proposed 4D-printed soft robot further ensures the sustainability of our approach, with immediate degradation rates of 96.6% within 72 h. The proposed 4D printing concept for FGMMs can create new opportunities for intelligent and sustainable additive manufacturing in soft robotics.

Lightweight porous materials with high load-bearing, damage tolerance and energy absorption (EA) as well as intelligence of shape recovery after material deformation are beneficial and critical for many applications, e.g. aerospace, automobiles, electronics, etc. Cuttlebone produced in the cuttlefish has evolved vertical walls with the optimal corrugation gradient, enabling stress homogenization, significant load bearing, and damage tolerance to protect the organism from high external pressures in the deep sea. This work illustrated that the complex hybrid wave shape in cuttlebone walls, becoming more tortuous from bottom to top, creates a lightweight, load-bearing structure with progressive failure. By mimicking the cuttlebone, a novel bionic hybrid structure (BHS) was proposed, and as a comparison, a regular corrugated structure and a straight wall structure were designed. Three types of designed structures have been successfully manufactured by laser powder bed fusion (LPBF) with NiTi powder. The LPBF-processed BHS exhibited a total porosity of 0.042% and a good dimensional accuracy with a peak deviation of 17.4 μ m. Microstructural analysis indicated that the LPBF-processed BHS had a strong (001) crystallographic orientation and an average size of 9.85 μ m. Mechanical analysis revealed the LPBF-processed BHS could withstand over 25 000 times its weight without significant deformation and had the highest specific EA value (5.32 J·g ^−1 ) due to the absence of stress concentration and progressive wall failure during compression. Cyclic compression testing showed that LPBF-processed BHS possessed superior viscoelastic and elasticity energy dissipation capacity. Importantly, the uniform reversible phase transition from martensite to austenite in the walls enables the structure to largely recover its pre-deformation shape when heated (over 99% recovery rate). These design strategies can serve as valuable references for the development of intelligent components that possess high mechanical efficiency and shape memory capabilities.

Metal matrix composites (MMCs) are frequently employed in various advanced industries due to their high modulus and strength, favorable wear and corrosion resistance, and other good properties at elevated temperatures. In recent decades, additive manufacturing (AM) technology has garnered attention as a potential way for fabricating MMCs. This article provides a comprehensive review of recent endeavors and progress in AM of MMCs, encompassing available AM technologies, types of reinforcements, feedstock preparation, synthesis principles during the AM process, typical AM-produced MMCs, strengthening mechanisms, challenges, and future interests. Compared to conventionally manufactured MMCs, AM-produced MMCs exhibit more uniformly distributed reinforcements and refined microstructure, resulting in comparable or even better mechanical properties. In addition, AM technology can produce bulk MMCs with significantly low porosity and fabricate geometrically complex MMC components and MMC lattice structures. As reviewed, many AM-produced MMCs, such as Al matrix composites, Ti matrix composites, nickel matrix composites, Fe matrix composites, etc, have been successfully produced. The types and contents of reinforcements strongly influence the properties of AM-produced MMCs, the choice of AM technology, and the applied processing parameters. In these MMCs, four primary strengthening mechanisms have been identified: Hall–Petch strengthening, dislocation strengthening, load transfer strengthening, and Orowan strengthening. AM technologies offer advantages that enhance the properties of MMCs when compared with traditional fabrication methods. Despite the advantages above, further challenges of AM-produced MMCs are still faced, such as new methods and new technologies for investigating AM-produced MMCs, the intrinsic nature of MMCs coupled with AM technologies, and challenges in the AM processes. Therefore, the article concludes by discussing the challenges and future interests of AM of MMCs.

The burgeoning interest in flexible electronics necessitates the creation of patterning technology specifically tailored for flexible substrates and complex surface morphologies. Among a variety of patterning techniques, transfer printing emerges as one of the most efficient, cost-effective, and scalable methods. It boasts the ability for high-throughput fabrication of 0–3D micro- and nano-structures on flexible substrates, working in tandem with traditional lithography methods. This review highlights the critical issue of transfer printing: the flawless transfer of devices during the pick-up and printing process. We encapsulate recent advancements in numerous transfer printing techniques, with a particular emphasis on strategies to control adhesion forces at the substrate/device/stamp interfaces. These strategies are employed to meet the requirements of competing fractures for successful pick-up and print processes. The mechanism, advantages, disadvantages, and typical applications of each transfer printing technique will be thoroughly discussed. The conclusion section provides design guidelines and probes potential directions for future advancements.

Ceramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geometries, extended processing durations, elevated porosity, and substantial shrinkage deformations. Direct additive manufacturing (dAM) technology stands out as a state-of-the-art solution for ceramic oxides production. It facilitates the one-step fabrication of high-performance, intricately designed components characterized by dense structures. Importantly, dAM eliminates the necessity for post-heat treatments, streamlining the manufacturing process and enhancing overall efficiency. This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides, with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques. A thorough investigation is conducted into the shaping quality, microstructure, and properties of diverse ceramic oxides produced through dAM. Critical examination is given to key aspects including feedstock preparation, laser-material coupling, formation and control of defects, in-situ monitoring and simulation. This paper concludes by outlining future trends and potential breakthrough directions, taking into account current gaps in this rapidly evolving field.

Triboelectric nanogenerators (TENGs), a type of promising micro/nano energy source, have been arousing tremendous research interest since their inception and have been the subject of many striking developments, including defining the fundamental physical mechanisms, expanding applications in mechanical to electric power conversion and self-powered sensors, etc. TENGs with a superior surface charge density at the interfaces of the electrodes and dielectrics are found to be crucial to the enhancement of the performance of the devices. Here, an overview of recent advances, including material optimization, circuit design, and strategy conjunction, in developing TENGs through surface charge enhancement is presented. In these topics, different strategies are retrospected in terms of charge transport and trapping mechanisms, technical merits, and limitations. Additionally, the current challenges in high-performance TENG research and the perspectives in this field are discussed.

With the arrival of intelligent terminals, triboelectric nanogenerators, as a new kind of energy converter, are considered one of the most important technologies for the next generation of intelligent electronics. As a self-powered sensor, it can greatly reduce the power consumption of the entire sensing system by transforming external mechanical energy to electricity. However, the fabrication method of triboelectric sensors largely determines their functionality and performance. This review provides an overview of various methods used to fabricate triboelectric sensors, with a focus on the processes of micro-electro-mechanical systems technology, three-dimensional printing, textile methods, template-assisted methods, and material synthesis methods for manufacturing. The working mechanisms and suitable application scenarios of various methods are outlined. Subsequently, the advantages and disadvantages of various methods are summarized, and reference schemes for the subsequent application of these methods are included. Finally, the opportunities and challenges faced by different methods are discussed, as well as their potential for application in various intelligent systems in the Internet of Things.

Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron x-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas; and (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced cavity mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.

Artificial sensory systems have emerged as pivotal technologies to bridge the gap between the virtual and real-world, replicating human senses to interact intelligently with external stimuli. To practically apply artificial sensory systems in the real-world, it is essential to mass-produce nanomaterials with ensured sensitivity and selectivity, purify them for desired functions, and integrate them into large-area sensory devices through assembly techniques. A comprehensive understanding of each process parameter from material processing to device assembly is crucial for achieving a high-performing artificial sensory system. This review provides a technological framework for fabricating high-performance artificial sensory systems, covering material processing to device integrations. We introduce recent approaches for dispersing and purifying various nanomaterials including 0D, 1D, and 2D nanomaterials. We then highlight advanced coating and printing techniques of the solution-processed nanomaterials based on representative three methods including (i) evaporation-based assembly, (ii) assisted assembly, and (iii) direct patterning. We explore the application and performances of these solution-processed materials and printing methods in fabricating sensory devices mimicking five human senses including vision, olfaction, gustation, hearing, and tactile perception. Finally, we suggest an outlook for possible future research directions to solve the remaining challenges of the artificial sensory systems such as ambient stability, device consistency, and integration with AI-based software.

Customized heat treatment is essential for enhancing the mechanical properties of additively manufactured metallic materials, especially for alloys with complex phase constituents and heterogenous microstructure. However, the interrelated evolutions of different microstructure features make it difficult to establish optimal heat treatment processes. Herein, we proposed a method for customized heat treatment process exploration and establishment to overcome this challenge for such kind of alloys, and a wire arc additively manufactured (WAAM) Mg-Gd-Y-Zn-Zr alloy with layered heterostructure was used for feasibility verification. Through this method, the optimal microstructures (fine grain, controllable amount of long period stacking ordered (LPSO) structure and nano-scale β ′ precipitates) and the corresponding customized heat treatment processes (520 °C/30 min + 200 °C/48 h) were obtained to achieve a good combination of a high strength of 364 MPa and a considerable elongation of 6.2%, which surpassed those of other state-of-the-art WAAM-processed Mg alloys. Furthermore, we evidenced that the favorable effect of the undeformed LPSO structures on the mechanical properties was emphasized only when the nano-scale β ′ precipitates were present. It is believed that the findings promote the application of magnesium alloy workpieces and help to establish customized heat treatment processes for additively manufactured materials.

Multimaterial (MM) 3D printing shows great potential for application in metamaterials, flexible electronics, biomedical devices and robots, since it can seamlessly integrate distinctive materials into one printed structure. Among numerous MM 3D printing technologies, digital light processing (DLP) MM 3D printing is compatible with a wide range of materials from hydrogels to ceramics, and can print MM 3D structures with high resolution, high complexity and fast speed. This paper introduces the fundamental mechanisms of DLP 3D printing, and reviews the recent advances of DLP MM 3D printing technologies with emphasis on material switching methods and material contamination issues. It also summarizes a number of typical examples of DLP MM 3D printing systems developed in the past decade, and introduces their system structures, working principles, material switching methods, residual resin removal methods, printing steps, as well as the representative structures and applications. Finally, we provide perspectives on the directions of the further development of DLP MM 3D printing technology.

Surface-enhanced Raman spectroscopy (SERS) microfluidic system, which enables rapid detection of chemical and biological analytes, offers an effective platform to monitor various food contaminants and disease diagnoses. The efficacy of SERS microfluidic systems is greatly dependent on the sensitivity and reusability of SERS detection substrates to ensure repeated use for prolonged periods. This study proposed a novel process of femtosecond laser nanoparticle array (NPA) implantation to achieve homogeneous forward transfer of gold NPA on a flexible polymer film and accurately integrated it within microfluidic chips for SERS detection. The implanted Au-NPA strips show a remarkable electromagnetic field enhancement with the factor of 9 × 10 ^8 during SERS detection of malachite green (MG) solution, achieving a detection limit lower than 10 ppt, far better than most laser-prepared SERS substrates. Furthermore, Au-NPA strips show excellent reusability after several physical and chemical cleaning, because of the robust embedment of laser-implanted NPA in flexible substrates. To demonstrate the performance of Au-NPA, a SERS microfluidic system is built to monitor the online oxidation reaction between MG/NaClO reactants, which helps infer the reaction path. The proposed method of nanoparticle implantation is more effective than the direct laser structuring technique. It provides better performance for SERS detection, robustness of detection, and substrate flexibility and has a wider range of applications for microfluidic systems without any negative impact.

Flexible electronics offer a multitude of advantages, such as flexibility, lightweight property, portability, and high durability. These unique properties allow for seamless applications to curved and soft surfaces, leading to extensive utilization across a wide range of fields in consumer electronics. These applications, for example, span integrated circuits, solar cells, batteries, wearable devices, bio-implants, soft robotics, and biomimetic applications. Recently, flexible electronic devices have been developed using a variety of materials such as organic, carbon-based, and inorganic semiconducting materials. Silicon (Si) owing to its mature fabrication process, excellent electrical, optical, thermal properties, and cost efficiency, remains a compelling material choice for flexible electronics. Consequently, the research on ultra-thin Si in the context of flexible electronics is studied rigorously nowadays. The thinning of Si is crucially important for flexible electronics as it reduces its bending stiffness and the resultant bending strain, thereby enhancing flexibility while preserving its exceptional properties. This review provides a comprehensive overview of the recent efforts in the fabrication techniques for forming ultra-thin Si using top-down and bottom-up approaches and explores their utilization in flexible electronics and their applications.

Innovative pulsed current-assisted multi-pass rolling tests were conducted on a 12-roll mill during the rolling deformation processing of SUS304 ultra-thin strips. The results show that in the first rolling pass, the rolling reduction rate of a conventionally rolled sample (at room temperature) is 33.8%, which can be increased to 41.5% by pulsed current-assisted rolling, enabling the formation of an ultra-thin strip with a size of 67.3 μ m in only one rolling pass. After three passes of pulsed current-assisted rolling, the thickness of the ultra-thin strip can be further reduced to 51.7 μ m. To clearly compare the effects of a pulsed current on the microstructure and mechanical response of the ultra-thin strip, ultra-thin strips with nearly the same thickness reduction were analyzed. It was found that pulsed current can reduce the degree of work-hardening of the rolled samples by promoting dislocation detachment, reducing the density of stacking faults, inhibiting martensitic phase transformation, and shortening the total length of grain boundaries. As a result, the ductility of ultra-thin strips can be effectively restored to approximately 16.3% while maintaining a high tensile strength of 1118 MPa.Therefore, pulsed current-assisted rolling deformation shows great potential for the formation of ultra-thin strips with a combination of high strength and ductility.

Over the course of millions of years, nature has evolved to ensure survival and presents us with a myriad of functional surfaces and structures that can boast high efficiency, multifunctionality, and sustainability. What makes these surfaces particularly practical and effective is the intricate micropatterning that enables selective interactions with microstructures. Most of these structures have been realized in the laboratory environment using numerous fabrication techniques by tailoring specific surface properties. Of the available manufacturing methods, additive manufacturing (AM) has created opportunities for fabricating these structures as the complex architectures of the naturally occurring microstructures far exceed the traditional ways. This paper presents a concise overview of the fundamentals of such patterned microstructured surfaces, their fabrication techniques, and diverse applications. A comprehensive evaluation of micro fabrication methods is conducted, delving into their respective strengths and limitations. Greater emphasis is placed on AM processes like inkjet printing and micro digital light projection printing due to the intrinsic advantages of these processes to additively fabricate high resolution structures with high fidelity and precision. The paper explores the various advancements in these processes in relation to their use in microfabrication and also presents the recent trends in applications like the fabrication of microlens arrays, microneedles, and tissue scaffolds.

Over the past two decades, superhydrophobic surfaces that are easily created have aroused considerable attention for their superior performances in various applications at room temperature. Nowadays, there is a growing demand in special fields for the development of surfaces that can resist wetting by high-temperature molten droplets (>1200 °C) using facile design and fabrication strategies. Herein, bioinspired directional structures (BDSs) were prepared on Y _2 O _3 -stabilized ZrO _2 (YSZ) surfaces using femtosecond laser ablation. Benefiting from the anisotropic energy barriers, the BDSs featured with no additional modifiers showed a remarkable increase from 9.2° to 60° in the contact angle of CaO–MgO–Al _2 O _3 –SiO _2 (CMAS) melt and a 70.1% reduction in the spreading area of CMAS at 1250 °C, compared with polished super-CMAS-melt-philic YSZ surfaces. Moreover, the BDSs demonstrated exceptional wetting inhibition even at 1 400 °C, with an increase from 3.3° to 31.3° in contact angle and a 67.9% decrease in spreading area. This work provides valuable insight and a facile preparation strategy for effectively inhibiting the wetting of molten droplets on super-melt-philic surfaces at extremely high temperatures.

Over millions of years of natural evolution, organisms have developed nearly perfect structures and functions. The self-fabrication of organisms serves as a valuable source of inspiration for designing the next-generation of structural materials, and is driving the future paradigm shift of modern materials science and engineering. However, the complex structures and multifunctional integrated optimization of organisms far exceed the capability of artificial design and fabrication technology, and new manufacturing methods are urgently needed to achieve efficient reproduction of biological functions. As one of the most valuable advanced manufacturing technologies of the 21st century, laser processing technology provides an efficient solution to the critical challenges of bionic manufacturing. This review outlines the processing principles, manufacturing strategies, potential applications, challenges, and future development outlook of laser processing in bionic manufacturing domains. Three primary manufacturing strategies for laser-based bionic manufacturing are elucidated: subtractive manufacturing, equivalent manufacturing, and additive manufacturing. The progress and trends in bionic subtractive manufacturing applied to micro/nano structural surfaces, bionic equivalent manufacturing for surface strengthening, and bionic additive manufacturing aiming to achieve bionic spatial structures, are reported. Finally, the key problems faced by laser-based bionic manufacturing, its limitations, and the development trends of its existing technologies are discussed.

3D printing techniques offer an effective method in fabricating complex radially multi-material structures. However, it is challenging for complex and delicate radially multi-material model geometries without supporting structures, such as tissue vessels and tubular graft, among others. In this work, we tackle these challenges by developing a polar digital light processing technique which uses a rod as the printing platform. The 3D model fabrication is accomplished through line projection. The rotation and translation of the rod are synchronized to project and illuminate the photosensitive material volume. By controlling the distance between the rod and the printing window, we achieved the printing of tubular structures with a minimum wall thickness as thin as 50 micrometers. By controlling the width of fine slits at the printing window, we achieved the printing of structures with a minimum feature size of 10 micrometers. Our process accomplished the fabrication of thin-walled tubular graft structure with a thickness of only 100 micrometers and lengths of several centimeters within a timeframe of just 100 s. Additionally, it enables the printing of axial multi-material structures, thereby achieving adjustable mechanical strength. This method is conducive to rapid customization of tubular grafts and the manufacturing of tubular components in fields such as dentistry, aerospace, and more.

Optical imaging systems have greatly extended human visual capabilities, enabling the observation and understanding of diverse phenomena. Imaging technologies span a broad spectrum of wavelengths from x-ray to radio frequencies and impact research activities and our daily lives. Traditional glass lenses are fabricated through a series of complex processes, while polymers offer versatility and ease of production. However, modern applications often require complex lens assemblies, driving the need for miniaturization and advanced designs with micro- and nanoscale features to surpass the capabilities of traditional fabrication methods. Three-dimensional (3D) printing, or additive manufacturing, presents a solution to these challenges with benefits of rapid prototyping, customized geometries, and efficient production, particularly suited for miniaturized optical imaging devices. Various 3D printing methods have demonstrated advantages over traditional counterparts, yet challenges remain in achieving nanoscale resolutions. Two-photon polymerization lithography (TPL), a nanoscale 3D printing technique, enables the fabrication of intricate structures beyond the optical diffraction limit via the nonlinear process of two-photon absorption within liquid resin. It offers unprecedented abilities, e.g. alignment-free fabrication, micro- and nanoscale capabilities, and rapid prototyping of almost arbitrary complex 3D nanostructures. In this review, we emphasize the importance of the criteria for optical performance evaluation of imaging devices, discuss material properties relevant to TPL, fabrication techniques, and highlight the application of TPL in optical imaging. As the first panoramic review on this topic, it will equip researchers with foundational knowledge and recent advancements of TPL for imaging optics, promoting a deeper understanding of the field. By leveraging on its high-resolution capability, extensive material range, and true 3D processing, alongside advances in materials, fabrication, and design, we envisage disruptive solutions to current challenges and a promising incorporation of TPL in future optical imaging applications.

Amid the growing interest in triboelectric nanogenerators (TENGs) as novel energy-harvesting devices, several studies have focused on direct current (DC) TENGs to generate a stable DC output for operating electronic devices. However, owing to the working mechanisms of conventional DC TENGs, generating a stable DC output from reciprocating motion remains a challenge. Accordingly, we propose a bidirectional rotating DC TENG (BiR-TENG), which can generate DC outputs, regardless of the direction of rotation, from reciprocating motions. The distinct design of the BiR-TENG enables the mechanical rectification of the alternating current output into a rotational-direction-dependent DC output. Furthermore, it allows the conversion of the rotational-direction-dependent DC output into a unidirectional DC output by adapting the configurations depending on the rotational direction. Owing to these tailored design strategies and subsequent optimizations, the BiR-TENG could generate an effective unidirectional DC output. Applications of the BiR-TENG for the reciprocating motions of swinging doors and waves were demonstrated by harnessing this output. This study demonstrates the potential of the BiR-TENG design strategy as an effective and versatile solution for energy harvesting from reciprocating motions, highlighting the suitability of DC outputs as an energy source for electronic devices.

Triboelectric materials with high charge density are the building-block for the commercial application of triboelectric nanogenerators (TENGs). Unstable dynamic processes influence the change of the charge density on the surface and inside of triboelectric materials. The charge density of triboelectric materials depends on the surface and the internal charge transfer processes. The focus of this review is on recent advances in high charge density triboelectric materials and advances in the fabrication of TENGs. We summarize the existing strategies for achieving high charge density in triboelectric materials as well as their fundamental properties. We then review current optimization methods for regulating dynamic charge transfer processes to increase the output charge density: first, increasing charge injection and limiting charge dissipation to achieve a high average surface charge density, and second, regulating the internal charge transfer process and storing charge in triboelectric materials to increase the output charge density. Finally, we present the challenges and prospects in developing high-performance triboelectric materials.

Zinc (Zn) is considered a promising biodegradable metal for implant applications due to its appropriate degradability and favorable osteogenesis properties. In this work, laser powder bed fusion (LPBF) additive manufacturing was employed to fabricate pure Zn with a heterogeneous microstructure and exceptional strength-ductility synergy. An optimized processing window of LPBF was established for printing Zn samples with relative densities greater than 99% using a laser power range of 80 ∼ 90 W and a scanning speed of 900 mm s ^−1 . The Zn sample printed with a power of 80 W at a speed of 900 mm s ^−1 exhibited a hierarchical heterogeneous microstructure consisting of millimeter-scale molten pool boundaries, micrometer-scale bimodal grains, and nanometer-scale pre-existing dislocations, due to rapid cooling rates and significant thermal gradients formed in the molten pools. The printed sample exhibited the highest ductility of ∼12.1% among all reported LPBF-printed pure Zn to date with appreciable ultimate tensile strength (∼128.7 MPa). Such superior strength-ductility synergy can be attributed to the presence of multiple deformation mechanisms that are primarily governed by heterogeneous deformation-induced hardening resulting from the alternative arrangement of bimodal Zn grains with pre-existing dislocations. Additionally, continuous strain hardening was facilitated through the interactions between deformation twins, grains and dislocations as strain accumulated, further contributing to the superior strength-ductility synergy. These findings provide valuable insights into the deformation behavior and mechanisms underlying exceptional mechanical properties of LPBF-printed Zn and its alloys for implant applications.

With the arrival of the era of artificial intelligence (AI) and big data, the explosive growth of data has raised higher demands on computer hardware and systems. Neuromorphic techniques inspired by biological nervous systems are expected to be one of the approaches to breaking the von Neumann bottleneck. Piezotronic neuromorphic devices modulate electrical transport characteristics by piezopotential and directly associate external mechanical motion with electrical output signals in an active manner, with the capability to sense/store/process information of external stimuli. In this review, we have presented the piezotronic neuromorphic devices (which are classified into strain-gated piezotronic transistors and piezoelectric nanogenerator-gated field effect transistors based on device structure) and discussed their operating mechanisms and related manufacture techniques. Secondly, we summarized the research progress of piezotronic neuromorphic devices in recent years and provided a detailed discussion on multifunctional applications, including bionic sensing, information storage, logic computing, and electrical/optical artificial synapses. Finally, in the context of future development, challenges, and perspectives, we have discussed how to modulate novel neuromorphic devices with piezotronic effects more effectively. It is believed that the piezotronic neuromorphic devices have great potential for the next generation of interactive sensation/memory/computation to facilitate the development of the Internet of Things, AI, biomedical engineering, etc.

Post-heat treatment is commonly employed to improve the microstructural homogeneity and enhance the mechanical performances of the additively manufactured metallic materials. In this work, a ternary (NiTi) _91 Nb _9 (at.%) shape memory alloy was produced by laser powder bed fusion (L-PBF) using pre-alloyed NiTi and elemental Nb powders. The effect of solution treatment on the microstructure, phase transformation behavior and mechanical/functional performances was investigated. The in-situ alloyed (NiTi) _91 Nb _9 alloy exhibits a submicron cellular-dendritic structure surrounding the supersaturated B2-NiTi matrix. Upon high-temperature (1273 K) solution treatment, Nb-rich precipitates were precipitated from the supersaturated matrix. The fragmentation and spheroidization of the NiTi/Nb eutectics occurred during solution treatment, leading to a morphological transition from mesh-like into rod-like and sphere-like. Coarsening of the β -Nb phases occurred with increasing holding time. The martensite transformation temperature increases after solution treatment, mainly attributed to: ( i ) reduced lattice distortion due to the Nb expulsion from the supersaturated B2-NiTi, and ( ii ) the Ti expulsion from the β -Nb phases that lowers the ratio Ni/Ti in the B2-NiTi matrix, which resulted from the microstructure changes from non-equilibrium to equilibrium state. The thermal hysteresis of the solutionized alloys is around 145 K after 20% pre-deformation, which is comparable to the conventional NiTiNb alloys. A short-term solution treatment (i.e. at 1 273 K for 30 min) enhances the ductility and strength of the as-printed specimen, with the increase of fracture stress from (613 ± 19) MPa to (781 ± 20) MPa and the increase of fracture strain from (7.6 ± 0.1)% to (9.5 ± 0.4)%. Both the as-printed and solutionized samples exhibit good tensile shape memory effects with recovery rates >90%. This work suggests that post-process heat treatment is essential to optimize the microstructure and improve the mechanical performances of the L-PBF in-situ alloyed parts.

Mg-Gd-Y-Zr alloy, as a typical magnesium rare-earth (Mg-RE) alloy, is gaining popularity in the advanced equipment manufacturing fields owing to its noticeable age-hardening properties and high specific strength. However, it is extremely challenging to prepare wrought components with large dimensions and complex shapes because of the poor room-temperature processability of Mg-Gd-Y-Zr alloy. Herein, we report a wire-arc directed energy deposited (DED) Mg-10.45Gd-2.27Y-0.52Zr (wt.%, GW102K) alloy with high RE content presenting a prominent combination of strength and ductility, realized by tailored nanoprecipitates through an optimized heat treatment procedure. Specifically, the solution-treated sample exhibits excellent ductility with an elongation (EL) of (14.6 ± 0.1)%, while the aging-treated sample at 200 °C for 58 h achieves an ultra-high ultimate tensile strength (UTS) of (371 ± 1.5) MPa. Besides, the aging-treated sample at 250 °C for 16 h attains a good strength-ductility synergy with a UTS of (316 ± 2.1) MPa and a EL of (8.5 ± 0.1)%. Particularly, the evolution mechanisms of precipitation response induced by various aging parameters and deformation behavior caused by nanoprecipitates type were also systematically revealed. The excellent ductility resulted from coordinating localized strains facilitated by active slip activity. And the ultra-high strength should be ascribed to the dense nano- β ′ hampering dislocation motion. Additionally, the shearable nano- β _1 contributed to the good strength-ductility synergy. This work thus offers insightful understanding into the nanoprecipitates manipulation and performance tailoring for the wire-arc DED preparation of large-sized Mg-Gd-Y-Zr components with complex geometries.