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Metal additive manufacturing (MAM) is an effective way to fabricate conformal cooling channels (CCCs), which follow the curves of the plastic product in the mold body of the plastic injection. CCCs have free-curved pathways thanks to the design & manufacturing flexibilities of the MAM process so that they can achieve better cooling performance with shorter cooling time and smaller temperature non-uniformity. On the other hand, the flexibilities of the MAM process bring multiple options for design variables and the high number of design variables make the final design of CCCs complex, high-cost, and time-consuming. Considering this challenge, this study presents the entire process of MAM of CCCs for a target product with eight different design variables, which makes it a product with a high number of design variables, from the initial design to the on-site manufacturing including the steps of computer-aided design & simulations, metamodel, multiobjective optimization, and the printing quality monitoring. The target product has three main objectives that are i) the temperature difference between the maximum and minimum values at the internal wall of the mold, ii) maximum temperature in the mold body, and iii) pressure drop. The optimized product is then printed via direct metal laser sintering (DMLS) machine and the quality check is done via X-ray computed tomography. Ministry of Education (MOE) This study is funded by the Ministry of Education Tier 1 RG154/19.

Sodium ion batteries are attractive for the rapidly emerging large-scale energy storage market for intermittent renewable resources. Currently a viable cathode material does not exist for practical non-aqueous sodium ion battery applications. Here we disclose a high performance, durable electrode material based on the 3D NASICON framework. Porous Na3V2(PO4)3/C was synthesized using a novel solution-based approach. This material, as a cathode, is capable of delivering an energy storage capacity of ∼400 mWh/g vs. sodium metal. Furthermore, at high current rates (10, 20 and 40 C), it displayed remarkable capacity retention. Equally impressive is the long term cycle life. Nearly 50% of the initial capacity was retained after 30,000 charge/discharge cycles at 40 C (4.7 A/g). Notably, coulombic efficiency was 99.68% (average) over the course of cycling. To the best of our knowledge, the combination of high energy density, high power density and ultra long cycle life demonstrated here has never been reported before for sodium ion batteries. We believe our findings will have profound implications for developing large-scale energy storage systems for renewable energy sources.

Metal oxide semiconductors are promising interfacial materials for organic photovoltaics (OPVs) because of their electrical properties and solution processability. In this article, we report the fabrication of poly(3-hexylthiophene):[6,6]-phenyl-C61 butyric acid methyl ester (P3HT:PCBM) OPV devices incorporating solution-based NiO interfacial layers that show promising enhancements of the device photocurrent and stability. We discuss the impact of parasitic shunt and series resistances on device performance as well as the ambient degradation of these devices, studied with intensity modulated photocurrent spectroscopy (IMPS). The results showed that charge extraction was predominantly affected by degradation via decrease in carrier mobility and increased trapping/recombination, revealing the physical mechanism behind the degradation observed. 2012 Elsevier Ltd. All rights reserved.

A critical component in bulk-heterojunction (BHJ) organic photovoltaics (OPVs) is the charge-selective interfacial layer, which plays a vital role in achieving high device performance and stability. Here, we present the performance of molybdenum oxide (MoOx) hole selective interfacial layers for BHJ OPVs based on poly(3-hexylthiophene) (P3HT) donor and [6,6]-phenyl-C61 butyric acid methyl ester (PCBM) acceptor, prepared by a facile, low-temperature solution process. The results showed that the MoOx films enhanced device efficiency and stability in comparison to reference devices containing the conventional poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) interfacial layer. Furthermore, a high fill factor (∼69%) close to the theoretical maximum value predicted for the P3HT:PCBM BHJ system was achieved. Despite their hole selective nature, ultraviolet photoemission spectroscopy (UPS) revealed that the MoOx films were n-type. This hole selective behavior can be explained by invoking band b...

The present work demonstrates the usefulness of nickel oxide as a hole transporting material in solid state dye-sensitized solar cells (SSDSSCs). We report on the photovoltaic performances of sensitized TiO2/NiO heterojunctions, and demonstrate that the TiO2 film thickness and morphology, as well as NiO film thickness, have significant effects on the photovoltaic behaviour of TiO2/NiO SSDSSC. Under 1 sun AM1.5G simulated illumination, the SSDSSCs demonstrated best photovoltaic performance with a short circuit photocurrent density, open circuit voltage, fill factor and efficiency of 0.91 mA cm−2, 780 mV, 40% and 0.3%, respectively. This study draws attention to the feasibility of enhancing the photovoltaic performance in SSDSSC devices through development of appropriately designed sensitized TiO2/NiO heterojunctions.

Organic solar cells based on poly(3-hexylthiophene) and [6,6]-phenyl-C61-butyric acid methyl ester were fabricated with electrodeposited TiOx electron extraction layers 5-180 nm thick. Electrodeposition under ambient conditions is an attractive, facile and viable approach to prepare metal oxide interfacial layers. The TiOx films obtained displayed a linear relationship between thickness and deposition time when fabricated under ambient conditions using an aqueous air stable peroxotitanium precursor. The precursor solution was prepared from titanium isopropoxide using a chelate process, which allowed water to be used as solvent due to considerably decreased sensitivity of the precursor solution towards hydrolysis. Highly conformal TiOx films, typically observed with vacuum deposition techniques, were obtained on the indium tin oxide substrate upon electrogeneration of OH(-) ions using H2O2 additive. Conversely, significantly rougher films with spherical growths were obtained using NO3(-) additives. Low temperature annealing at 200 °C in air was found to greatly improve purity and O stoichiometry of the TiOx films, enabling efficient devices incorporating the electrodeposited TiOx to be made. Using MoOx as the hole extraction layer, the maximum power conversion efficiency obtained was 3.8% (Voc = 610 mV; Jsc = 10.6 mA/cm(2); FF = 59%) under simulated 100 mW/cm(2) (AM1.5G) solar irradiation, whereas an efficiency of 3.4% was achieved with fully solution processed interfacial layers comprising the electrodeposited TiOx films and a surfactant-modified PEDOT:PSS hole extraction layer.