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Abstract The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain refinement, and enhance mechanical performance in metal components. Whereas it is evident that the formation of such microstructural features is affected by the melt pool behavior, the specific mechanisms by which ultrasonic vibration (UV) influences the melt pool remain elusive. In the present investigation, UV was applied in situ to DED of 316L stainless steel single tracks and bulk parts. For the first time, high-speed video imaging and thermal imaging were implemented in situ to quantitatively correlate the application of UV to melt pool evolution in DED. Extensive imaging data were coupled with in-depth microstructural characterization to develop a statistically robust dataset describing the observed phenomena. Our findings show that UV increases the melt pool peak temperature and dimensions, while improving the wettability of injected particles with the melt pool surface and reducing particle residence time. Near the substrate, we observe that UV results in a 92% decrease in porosity, and a 54% decrease in dendritic arm spacing. The effect of UV on the melt pool is caused by the combined mechanisms of acoustic cavitation, ultrasound absorption, and acoustic streaming. Through in situ imaging we demonstrate quantitatively that these phenomena, acting simultaneously, effectively diminish with increasing build height and size due to acoustic attenuation, consequently decreasing the positive effect of implementing UV-A DED. Thus, this research provides valuable insight into the value of in situ imaging, as well as the effects of UV on DED melt pool dynamics, the stochastic interactions between the melt pool and incoming powder particles, and the limitations of build geometry on the UV-A DED technique.

Architected strut-based metamaterials fabricated via three-dimensional printing exhibit a wide range of geometric and material heterogeneity, including variations in strut size, surface roughness, embedded micro-cracks and disconnected struts. The locations and severity of these defects are highly variable; combined with the complexity of the structure itself, it is exceedingly difficult to identify critical defects that limit performance and inform qualification protocols. To address this challenge, we consider the impact of distributions of defects for various strut-based lattice topologies. The role of defects is analyzed using Weibull distributions of strut failure strains. We relate the statistical distributions of strut properties to macroscopic stress-strain performance, using high through-put finite element predictions in thousands of virtual tests. Increasing the prevalence of defects decreases macroscopic strength; however, this has the complementary effect of introducing apparent ductility, i.e. load capacity even after the onset of strut failures. Hence, there is a trade-off between achieving high strength and gradual loss of stiffness that is desirable for thermal loading or lattice cores. Predictions of average strength as a function of Weibull modulus provide knock-down factors relative to the defect-free strength. In turn, these clearly identify quantitative processing targets to mitigate the impact of defects.

Mechanical characterization of ceramics is challenging, as the statistical nature of their strength requires numerous specimens to extract reliable distribution parameters. Here, we first propose a high-throughput testing procedure that allows extraction of statistical information on the strength of ceramic materials. We process large numbers of bending specimens from low volumes of material via Direct Ink Writing (DIW), and rapidly characterize them to extract Weibull parameters for bending strength. After investigating five ceramics and downselecting two formulations, we develop a multi-scale procedure to explore the impact of printing-induced defects on the strength distribution of DIW-processed ceramics. Finally, we demonstrate that a judicious choice of the printing strategy produces porous architected structures which can significantly exceed the strength of fully dense DIW-produced monolithic materials. While the results are presented on DIW-processed alumina-based ceramics, the approach is versatile and can provide rapid statistical data on the strength of many ceramic materials.

Metamaterials are engineered materials with unusual, unique properties and advanced functionalities that are a direct consequence of their microarchitecture. While initial properties and functionalities were limited to optics and electromagnetism, many novel categories of metamaterials that have applications in many different areas of research and practice, including acoustic, mechanics, biomaterials, and thermal engineering, have appeared in the last decade. This editorial serves as a prelude to the special issue with the same title that presents a number of selected studies in these directions. In particular, we review some of the most important developments in the design and fabrication of metamaterials with an emphasis on the more recent categories. We also suggest some directions for future research.

Plate-lattices are predicted to reach the upper bounds of strength and stiffness compared to traditional beam-lattices, but they are difficult to manufacture. Here, the authors use two-photon polymerization 3D-printing and pyrolysis to make carbon plate-nanolattices which reach those theoretical bounds, making them up to 639% stronger than beam-nanolattices.

Large bone fractures often require porous implants for complete healing. In this work, we numerically investigate the suitability of three topologically very different architected materials for long bone implants: the octet truss-based lattice, the Schwartz P minimal surface-based lattice and the spinodal stochastic surface-based lattice. Each implant topology (reinforcement) and its surrounding tissue (soft matrix) are modeled as a composite system via finite element analysis. Performance metrics are defined based on the Young’s modulus, the peak stress under service conditions, the interfacial surface area per unit volume and the relative bone growth rate (estimated based on the strain transferred to the soft matrix). We show that surface-based topologies are less prone to fatigue failure and may promote superior bone growth than conventional truss-based designs. Spinodal surface-based architected materials have the best performance, and can be fabricated via self-assembly approaches followed by material conversion, potentially allowing scalable fabrication of implants with unit cell sizes at the micro-scale, thus dramatically amplifying surface area per unit volume and bone growth efficiency.

While over the past decade architected cellular materials have been shown to possess unique mechanical properties, their thermal properties have received relatively little attention. Here, we investigate thermal transport in hollow nickel microlattices as a function of temperature and mechanical loading using infrared thermography. The effective thermal conductivity of hollow nickel microlattices with 99.9% porosity and 1 µm layer thickness is as low as 0.049 W m−1 K−1 at 320 K and increases to 0.075 W m−1 K−1 at 480 K, an increase we attribute to internal thermal radiation. By measuring the emissivity and using the Stephan-Boltzmann law, we estimate the contribution of thermal radiation in the effective thermal conductivity to range from 20% at 320 K to 49% at 480 K. The high porosity of microlattices strongly limits solid conduction and makes surface radiation very important in thermal transport. We further explore the impact of the strut surface condition by comparing hollow doped nickel microlattices with a smooth surface to those with a rough surface: the emissivity increases from 0.24 to 0.43, leading to increased thermal radiation contributions of 41% at 320 K to 58% at 480 K. Under mechanical loading, as the strain increases from 0% to 50%, decreasing the angle between the struts and the horizontal plane from 60° to 38°, the effective thermal conductivity decreases from 0.049 W m−1 K−1 to 0.016 W m−1 K−1. These findings indicate that architected cellular materials provide an excellent platform to control thermal properties independently on mechanical properties and to potentially develop thermal and thermomechanical metamaterials.

An amendment to this paper has been published and can be accessed via a link at the top of the paper.

Methods for tuning extracellular matrix (ECM) mechanics in 3D cell culture that rely on increasing the concentration of either protein or cross-linking molecules fail to control important parameters such as pore size, ligand density, and molecular diffusivity. Alternatively, ECM stiffness can be modulated independently from protein concentration by mechanically loading the ECM. We have developed a novel device for generating stiffness gradients in naturally derived ECMs, where stiffness is tuned by inducing strain, while local mechanical properties are directly determined by laser tweezers based active microrheology (AMR). Hydrogel substrates polymerized within 35 mm diameter Petri dishes are strained non-uniformly by the precise rotation of an embedded cylindrical post, and exhibit a position-dependent stiffness with little to no modulation of local mesh geometry. Here we present the device in the context of fibrin hydrogels. First AMR is used to directly measure local micromechanics in unstrained hydrogels of increasing fibrin concentration. Changes in stiffness are then mapped within our device, where fibrin concentration is held constant. Fluorescence confocal imaging and orbital particle tracking are used to quantify structural changes in fibrin on the micro and nano levels respectively. The micromechanical strain stiffening measured by microrheology is not accompanied by ECM microstructural changes under our applied loads, as measured by confocal microscopy. However, super-resolution orbital tracking reveals nanostructural straightening, lengthening, and reduced movement of fibrin fibers. Furthermore, we show that aortic smooth muscle cells cultured within our device are morphologically sensitive to the induced mechanical gradient. Our results demonstrate a powerful cell culture tool that can be used in the study of mechanical effects on cellular physiology in naturally derived 3D ECM tissues.

Ordered periodic microlattices with densities from 0.5 mg/cm3 to 500 mg/cm3 are fabricated by depositing various thin film materials (Au, Cu, Ni, SiO2, poly(C8H4F4)) onto sacrificial polymer lattice templates. Young's modulus and strength are measured in compression and the density scaling is determined. At low relative densities, recovery from compressive strains of 50% and higher is observed, independent of lattice material. An analytical model is shown to accurately predict the transition between recoverable “pseudo-superelastic” and irrecoverable plastic deformation for all constituent materials. These materials are of interest for energy storage applications, deployable structures, and for acoustic, shock, and vibration damping.