Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.

Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.

By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.

In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.

This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.

“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.

Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The research appears today in Nature Light Science and Applications.

Printing with a chip

Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.

Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.

They wondered if such a device could be used for a chip-based 3D printer.

At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.

“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”

Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.

When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.

A collaborative approach

But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.

Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.

A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.

The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.

But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.

The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.

In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.

Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.

“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

This work was funded, in part, by the U.S. National Science Foundation, the U.S. Defense Advanced Research Projects Agency, the Robert A. Welch Foundation, the MIT Rolf G. Locher Endowed Fellowship, and the MIT Frederick and Barbara Cronin Fellowship.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.

Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.

By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.

In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.

This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.

“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.

Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The research appears today in Nature Light Science and Applications.

Printing with a chip

Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.

Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.

They wondered if such a device could be used for a chip-based 3D printer.

At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.

“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”

Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.

When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.

A collaborative approach

But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.

Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.

A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.

The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.

But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.

The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.

In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.

Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.

“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

This work was funded, in part, by the U.S. National Science Foundation, the U.S. Defense Advanced Research Projects Agency, the Robert A. Welch Foundation, the MIT Rolf G. Locher Endowed Fellowship, and the MIT Frederick and Barbara Cronin Fellowship.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.

Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.

By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.

In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.

This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.

“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.

Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The research appears today in Nature Light Science and Applications.

Printing with a chip

Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.

Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.

They wondered if such a device could be used for a chip-based 3D printer.

At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.

“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”

Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.

When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.

A collaborative approach

But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.

Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.

A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.

The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.

But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.

The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.

In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.

Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.

“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

This work was funded, in part, by the U.S. National Science Foundation, the U.S. Defense Advanced Research Projects Agency, the Robert A. Welch Foundation, the MIT Rolf G. Locher Endowed Fellowship, and the MIT Frederick and Barbara Cronin Fellowship.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.

Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.

By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.

In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.

This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.

“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.

Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The research appears today in Nature Light Science and Applications.

Printing with a chip

Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.

Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.

They wondered if such a device could be used for a chip-based 3D printer.

At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.

“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”

Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.

When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.

A collaborative approach

But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.

Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.

A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.

The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.

But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.

The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.

In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.

Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.

“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

This work was funded, in part, by the U.S. National Science Foundation, the U.S. Defense Advanced Research Projects Agency, the Robert A. Welch Foundation, the MIT Rolf G. Locher Endowed Fellowship, and the MIT Frederick and Barbara Cronin Fellowship.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

Imagine a portable 3D printer you could hold in the palm of your hand. The tiny device could enable a user to rapidly create customized, low-cost objects on the go, like a fastener to repair a wobbly bicycle wheel or a component for a critical medical operation.

Researchers from MIT and the University of Texas at Austin took a major step toward making this idea a reality by demonstrating the first chip-based 3D printer. Their proof-of-concept device consists of a single, millimeter-scale photonic chip that emits reconfigurable beams of light into a well of resin that cures into a solid shape when light strikes it.

The prototype chip has no moving parts, instead relying on an array of tiny optical antennas to steer a beam of light. The beam projects up into a liquid resin that has been designed to rapidly cure when exposed to the beam’s wavelength of visible light.

By combining silicon photonics and photochemistry, the interdisciplinary research team was able to demonstrate a chip that can steer light beams to 3D print arbitrary two-dimensional patterns, including the letters M-I-T. Shapes can be fully formed in a matter of seconds.

In the long run, they envision a system where a photonic chip sits at the bottom of a well of resin and emits a 3D hologram of visible light, rapidly curing an entire object in a single step.

This type of portable 3D printer could have many applications, such as enabling clinicians to create tailor-made medical device components or allowing engineers to make rapid prototypes at a job site.

“This system is completely rethinking what a 3D printer is. It is no longer a big box sitting on a bench in a lab creating objects, but something that is handheld and portable. It is exciting to think about the new applications that could come out of this and how the field of 3D printing could change,” says senior author Jelena Notaros, the Robert J. Shillman Career Development Professor in Electrical Engineering and Computer Science (EECS), and a member of the Research Laboratory of Electronics.

Joining Notaros on the paper are Sabrina Corsetti, lead author and EECS graduate student; Milica Notaros PhD ’23; Tal Sneh, an EECS graduate student; Alex Safford, a recent graduate of the University of Texas at Austin; and Zak Page, an assistant professor in the Department of Chemical Engineering at UT Austin. The research appears today in Nature Light Science and Applications.

Printing with a chip

Experts in silicon photonics, the Notaros group previously developed integrated optical-phased-array systems that steer beams of light using a series of microscale antennas fabricated on a chip using semiconductor manufacturing processes. By speeding up or delaying the optical signal on either side of the antenna array, they can move the beam of emitted light in a certain direction.

Such systems are key for lidar sensors, which map their surroundings by emitting infrared light beams that bounce off nearby objects. Recently, the group has focused on systems that emit and steer visible light for augmented-reality applications.

They wondered if such a device could be used for a chip-based 3D printer.

At about the same time they started brainstorming, the Page Group at UT Austin demonstrated specialized resins that can be rapidly cured using wavelengths of visible light for the first time. This was the missing piece that pushed the chip-based 3D printer into reality.

“With photocurable resins, it is very hard to get them to cure all the way up at infrared wavelengths, which is where integrated optical-phased-array systems were operating in the past for lidar,” Corsetti says. “Here, we are meeting in the middle between standard photochemistry and silicon photonics by using visible-light-curable resins and visible-light-emitting chips to create this chip-based 3D printer. You have this merging of two technologies into a completely new idea.”

Their prototype consists of a single photonic chip containing an array of 160-nanometer-thick optical antennas. (A sheet of paper is about 100,000 nanometers thick.) The entire chip fits onto a U.S. quarter.

When powered by an off-chip laser, the antennas emit a steerable beam of visible light into the well of photocurable resin. The chip sits below a clear slide, like those used in microscopes, which contains a shallow indentation that holds the resin. The researchers use electrical signals to nonmechanically steer the light beam, causing the resin to solidify wherever the beam strikes it.

A collaborative approach

But effectively modulating visible-wavelength light, which involves modifying its amplitude and phase, is especially tricky. One common method requires heating the chip, but this is inefficient and takes a large amount of physical space.

Instead, the researchers used liquid crystal to fashion compact modulators they integrate onto the chip. The material’s unique optical properties enable the modulators to be extremely efficient and only about 20 microns in length.

A single waveguide on the chip holds the light from the off-chip laser. Running along the waveguide are tiny taps which tap off a little bit of light to each of the antennas.

The researchers actively tune the modulators using an electric field, which reorients the liquid crystal molecules in a certain direction. In this way, they can precisely control the amplitude and phase of light being routed to the antennas.

But forming and steering the beam is only half the battle. Interfacing with a novel photocurable resin was a completely different challenge.

The Page Group at UT Austin worked closely with the Notaros Group at MIT, carefully adjusting the chemical combinations and concentrations to zero-in on a formula that provided a long shelf-life and rapid curing.

In the end, the group used their prototype to 3D print arbitrary two-dimensional shapes within seconds.

Building off this prototype, they want to move toward developing a system like the one they originally conceptualized — a chip that emits a hologram of visible light in a resin well to enable volumetric 3D printing in only one step.

“To be able to do that, we need a completely new silicon-photonics chip design. We already laid out a lot of what that final system would look like in this paper. And, now, we are excited to continue working towards this ultimate demonstration,” Jelena Notaros says.

This work was funded, in part, by the U.S. National Science Foundation, the U.S. Defense Advanced Research Projects Agency, the Robert A. Welch Foundation, the MIT Rolf G. Locher Endowed Fellowship, and the MIT Frederick and Barbara Cronin Fellowship.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.

An intricate, honeycomb-like structure of struts and beams could withstand a supersonic impact better than a solid slab of the same material. What’s more, the specific structure matters, with some being more resilient to impacts than others.

That’s what MIT engineers are finding in experiments with microscopic metamaterials — materials that are intentionally printed, assembled, or otherwise engineered with microscopic architectures that give the overall material exceptional properties.

In a study appearing today in the Proceedings of the National Academy of Sciences, the engineers report on a new way to quickly test an array of metamaterial architectures and their resilience to supersonic impacts.

In their experiments, the team suspended tiny printed metamaterial lattices between microscopic support structures, then fired even tinier particles at the materials, at supersonic speeds. With high-speed cameras, the team then captured images of each impact and its aftermath, with nanosecond precision.

Their work has identified a few metamaterial architectures that are more resilient to supersonic impacts compared to their entirely solid, nonarchitected counterparts. The researchers say the results they observed at the microscopic level can be extended to comparable macroscale impacts, to predict how new material structures across length scales will withstand impacts in the real world.

“What we’re learning is, the microstructure of your material matters, even with high-rate deformation,” says study author Carlos Portela, the Brit and Alex d’Arbeloff Career Development Professor in Mechanical Engineering at MIT. “We want to identify impact-resistant structures that can be made into coatings or panels for spacecraft, vehicles, helmets, and anything that needs to be lightweight and protected.”

Other authors on the study include first author and MIT graduate student Thomas Butruille, and Joshua Crone of DEVCOM Army Research Laboratory.

Pure impact

The team’s new high-velocity experiments build off their previous work, in which the engineers tested the resilience of an ultralight, carbon-based material. That material, which was thinner than the width of a human hair, was made from tiny struts and beams of carbon, which the team printed and placed on a glass slide. They then fired microparticles toward the material, at velocities exceeding the speed of sound.  

Those supersonic experiments revealed that the microstructured material withstood the high-velocity impacts, sometimes deflecting the microparticles and other times capturing them.

“But there were many questions we couldn’t answer because we were testing the materials on a substrate, which may have affected their behavior,” Portela says.

In their new study, the researchers developed a way to test freestanding metamaterials, to observe how the materials withstand impacts purely on their own, without a backing or supporting substrate.

In their current setup, the researchers suspend a metamaterial of interest between two microscopic pillars made from the same base material. Depending on the dimensions of the metamaterial being tested, the researchers calculate how far apart the pillars must be in order to support the material at either end while allowing the material to respond to any impacts, without any influence from the pillars themselves.

“This way, we ensure that we’re measuring the material property and not the structural property,” Portela says.

Once the team settled on the pillar support design, they moved on to test a variety of metamaterial architectures. For each architecture, the researchers first printed the supporting pillars on a small silicon chip, then continued printing the metamaterial as a suspended layer between the pillars.

“We can print and test hundreds of these structures on a single chip,” Portela says.

Punctures and cracks

The team printed suspended metamaterials that resembled intricate honeycomb-like cross-sections. Each material was printed with a specific three-dimensional microscopic architecture, such as a precise scaffold of repeating octets, or more faceted polygons. Each repeated unit measured as small as a red blood cell. The resulting metamaterials were thinner than the width of a human hair.

The researchers then tested each metamaterial’s impact resilience by firing glass microparticles toward the structures, at speeds of up to 900 meters per second (more than 2,000 miles per hour) — well within the supersonic range. They caught each impact on camera and studied the resulting images, frame by frame, to see how the projectiles penetrated each material. Next, they examined the materials under a microscope and compared each impact’s physical aftermath.

“In the architected materials, we saw this morphology of small cylindrical craters after impact,” Portela says. “But in solid materials, we saw a lot of radial cracks and bigger chunks of material that were gouged out.”

Overall, the team observed that the fired particles created small punctures in the latticed metamaterials, and the materials nevertheless stayed intact. In contrast, when the same particles were fired at the same speeds into solid, nonlatticed materials of equal mass, they created large cracks that quickly spread, causing the material to crumble. The microstructured materials, therefore, were more efficient in resisting supersonic impacts as well as protecting against multiple impact events. And in particular, materials that were printed with the repeating octets appeared to be the most hardy.

“At the same velocity, we see the octet architecture is harder to fracture, meaning that the metamaterial, per unit mass, can withstand impacts up to twice as much as the bulk material,” Portela says. “This tells us that there are some architectures that can make a material tougher which can offer better impact protection.”

Going forward, the team plans to use the new rapid testing and analysis method to identify new metamaterial designs, in hopes of tagging architectures that can be scaled up to stronger and lighter protective gear, garments, coatings, and paneling.

“What I’m most excited about is showing we can do a lot of these extreme experiments on a benchtop,” Portela says. “This will significantly accelerate the rate at which we can validate new, high-performing, resilient materials.”

This work was funded, in part, by DEVCOM ARL Army Research Office through the MIT Institute for Soldier Nanotechnologies (ISN), and carried out, in part, using ISN’s and MIT.nano’s facilities. 

MIT researchers have used 3D printing to produce self-heating microfluidic devices, demonstrating a technique which could someday be used to rapidly create cheap, yet accurate, tools to detect a host of diseases.

Microfluidics, miniaturized machines that manipulate fluids and facilitate chemical reactions, can be used to detect disease in tiny samples of blood or fluids. At-home test kits for Covid-19, for example, incorporate a simple type of microfluidic.

But many microfluidic applications require chemical reactions that must be performed at specific temperatures. These more complex microfluidic devices, which are typically manufactured in a clean room, are outfitted with heating elements made from gold or platinum using a complicated and expensive fabrication process that is difficult to scale up.

Instead, the MIT team used multimaterial 3D printing to create self-heating microfluidic devices with built-in heating elements, through a single, inexpensive manufacturing process. They generated devices that can heat fluid to a specific temperature as it flows through microscopic channels inside the tiny machine.

Their technique is customizable, so an engineer could create a microfluidic that heats fluid to a certain temperature or given heating profile within a specific area of the device. The low-cost fabrication process requires about $2 of materials to generate a ready-to-use microfluidic.

The process could be especially useful in creating self-heating microfluidics for remote regions of developing countries where clinicians may not have access to the expensive lab equipment required for many diagnostic procedures.

“Clean rooms in particular, where you would usually make these devices, are incredibly expensive to build and to run. But we can make very capable self-heating microfluidic devices using additive manufacturing, and they can be made a lot faster and cheaper than with these traditional methods. This is really a way to democratize this technology,” says Luis Fernando Velásquez-García, a principal scientist in MIT’s Microsystems Technology Laboratories (MTL) and senior author of a paper describing the fabrication technique.

He is joined on the paper by lead author Jorge Cañada Pérez-Sala, an electrical engineering and computer science graduate student. The research will be presented at the PowerMEMS Conference this month.

An insulator becomes conductive

This new fabrication process utilizes a technique called multimaterial extrusion 3D printing, in which several materials can be squirted through the printer’s many nozzles to build a device layer by layer. The process is monolithic, which means the entire device can be produced in one step on the 3D printer, without the need for any post-assembly.

To create self-heating microfluidics, the researchers used two materials — a biodegradable polymer known as polylactic acid (PLA) that is commonly used in 3D printing, and a modified version of PLA.

The modified PLA has mixed copper nanoparticles into the polymer, which converts this insulating material into an electrical conductor, Velásquez-García explains. When electrical current is fed into a resistor composed of this copper-doped PLA, energy is dissipated as heat.

“It is amazing when you think about it because the PLA material is a dielectric, but when you put in these nanoparticle impurities, it completely changes the physical properties. This is something we don’t fully understand yet, but it happens and it is repeatable,” he says.

Using a multimaterial 3D printer, the researchers fabricate a heating resistor from the copper-doped PLA and then print the microfluidic device, with microscopic channels through which fluid can flow, directly on top in one printing step. Because the components are made from the same base material, they have similar printing temperatures and are compatible.

Heat dissipated from the resistor will warm fluid flowing through the channels in the microfluidic.

In addition to the resistor and microfluidic, they use the printer to add a thin, continuous layer of PLA that is sandwiched between them. It is especially challenging to manufacture this layer because it must be thin enough so heat can transfer from the resistor to the microfluidic, but not so thin that fluid could leak into the resistor.

The resulting machine is about the size of a U.S. quarter and can be produced in a matter of minutes. Channels about 500 micrometers wide and 400 micrometers tall are threaded through the microfluidic to carry fluid and facilitate chemical reactions.

Importantly, the PLA material is translucent, so fluid in the device remains visible. Many processes rely on visualization or the use of light to infer what is happening during chemical reactions, Velásquez-García explains.

Customizable chemical reactors

The researchers used this one-step manufacturing process to generate a prototype that could heat fluid by 4 degrees Celsius as it flowed between the input and the output. This customizable technique could enable them to make devices which would heat fluids in certain patterns or along specific gradients.

“You can use these two materials to create chemical reactors that do exactly what you want. We can set up a particular heating profile while still having all the capabilities of the microfluidic,” he says.

However, one limitation comes from the fact that PLA can only be heated to about 50 degrees Celsius before it starts to degrade. Many chemical reactions, such as those used for polymerase chain reaction (PCR) tests, require temperatures of 90 degrees or higher. And to precisely control the temperature of the device, researchers would need to integrate a third material that enables temperature sensing.

In addition to tackling these limitations in future work, Velásquez-García wants to print magnets directly into the microfluidic device. These magnets could enable chemical reactions that require particles to be sorted or aligned.

At the same time, he and his colleagues are exploring the use of other materials that could reach higher temperatures. They are also studying PLA to better understand why it becomes conductive when certain impurities are added to the polymer.

“If we can understand the mechanism that is related to the electrical conductivity of PLA, that would greatly enhance the capability of these devices, but it is going to be a lot harder to solve than some other engineering problems,” he adds.

“In Japanese culture, it’s often said that beauty lies in simplicity. This sentiment is echoed by the work of Cañada and Velasquez-Garcia. Their proposed monolithically 3D-printed microfluidic systems embody simplicity and beauty, offering a wide array of potential derivations and applications that we foresee in the future,” says Norihisa Miki, a professor of mechanical engineering at Keio University in Tokyo, who was not involved with this work.

“Being able to directly print microfluidic chips with fluidic channels and electrical features at the same time opens up very exiting applications when processing biological samples, such as to amplify biomarkers or to actuate and mix liquids. Also, due to the fact that PLA degrades over time, one can even think of implantable applications where the chips dissolve and resorb over time,” adds Niclas Roxhed, an associate professor at Sweden’s KTH Royal Institute of Technology, who was not involved with this study.

This research was funded, in part, by the Empiriko Corporation and a fellowship from La Caixa Foundation.