André R. Studart

Bioinspired Design and Assembly of Platelet Reinforced Polymer Films

Although strong and stiff human-made composites have long been developed, the microstructure of todays most advanced composites has yet to achieve the order and sophisticated hierarchy of hybrid materials built up by living organisms in nature. Clay-based nanocomposites with layered structure can reach notable stiffness and strength, but these properties are usually not accompanied by the ductility and flaw tolerance found in the structures generated by natural hybrid materials. By using principles found in natural composites, we showed that layered hybrid films combining high tensile strength and ductile behavior can be obtained through the bottom-up colloidal assembly of strong submicrometer-thick ceramic platelets within a ductile polymer matrix.

Composites Reinforced in Three Dimensions by Using Low Magnetic Fields

Dispersal in 3D The fabrication of composites containing small proportions of nanoparticles is limited by the ability to disperse the particles uniformly in all three dimensions. Erb et al. (p. 199; see the Perspective by Fratzl) describe a process for creating nanoparticle composites in which a magnetic field is used to align the nanoparticles. Surprisingly, the magnetic alignment of iron-oxide functionalized nanorods and discs was enabled using very small magnetic fields and low-volume fractions of magnetic nanoparticles, which allowed control of the orientation of the nanorods and discs three-dimensionally. Iron oxide−coated rods and platelets can reinforce a polymer composite through alignment with magnetic fields. The orientation and distribution of reinforcing particles in artificial composites are key to enable effective reinforcement of the material in mechanically loaded directions, but remain poor if compared to the distinctive architectures present in natural structural composites such as teeth, bone, and seashells. We show that micrometer-sized reinforcing particles coated with minimal concentrations of superparamagnetic nanoparticles (0.01 to 1 volume percent) can be controlled by using ultralow magnetic fields (1 to 10 milliteslas) to produce synthetic composites with tuned three-dimensional orientation and distribution of reinforcements. A variety of structures can be achieved with this simple method, leading to composites with tailored local reinforcement, wear resistance, and shape memory effects.

Self-shaping composites with programmable bioinspired microstructures

Shape change is a prevalent function apparent in a diverse set of natural structures, including seed dispersal units, climbing plants and carnivorous plants. Many of these natural materials change shape by using cellulose microfibrils at specific orientations to anisotropically restrict the swelling/shrinkage of their organic matrices upon external stimuli. This is in contrast to the material-specific mechanisms found in synthetic shape-memory systems. Here we propose a robust and universal method to replicate this unusual shape-changing mechanism of natural systems in artificial bioinspired composites. The technique is based upon the remote control of the orientation of reinforcing inorganic particles within the composite using a weak external magnetic field. Combining this reinforcement orientational control with swellable/shrinkable polymer matrices enables the creation of composites whose shape change can be programmed into the materials microstructure rather than externally imposed. Such bioinspired approach can generate composites with unusual reversibility, twisting effects and site-specific programmable shape changes.

Towards high-performance bioinspired composites.

Biological composites have evolved elaborate hierarchical structures to achieve outstanding mechanical properties using weak but readily available building blocks. Combining the underlying design principles of such biological materials with the rich chemistry accessible in synthetic systems may enable the creation of artificial composites with unprecedented properties and functionalities. This bioinspired approach requires identification, understanding, and quantification of natural design principles and their replication in synthetic materials, taking into account the intrinsic properties of the stronger artificial building blocks and the boundary conditions of engineering applications. In this progress report, the scientific and technological questions that have to be addressed to achieve this goal are highlighted, and examples of recent research efforts to tackle them are presented. These include the local characterization of the heterogeneous architecture of biological materials, the investigation of structure-function relationships to help unveil natural design principles, and the development of synthetic processing routes that can potentially be used to implement some of these principles in synthetic materials. The importance of replicating the design principles of biological materials rather than their structure per se is highlighted, and possible directions for further progress in this fascinating, interdisciplinary field are discussed.

Droplet Microfluidics for Fabrication of Non-Spherical Particles

We describe new developments for controlled fabrication of monodisperse non-spherical particles using droplet microfluidics. The high degree of control afforded by microfluidic technologies enables generation of single and multiple emulsion droplets. We show that these droplets can be transformed to non-spherical particles through further simple, spontaneous processing steps, including arrested coalescence, asymmetric polymer solidification, polymerization in microfluidic flow, and evaporation-driven clustering. These versatile and scalable microfluidic approaches can be used for producing large quantities of non-spherical particles that are monodisperse in both size and shape; these have great potential for commercial applications.

Stabilization of Oil-in-Water Emulsions by Colloidal Particles Modified with Short Amphiphiles

Emulsions stabilized through the adsorption of colloidal particles at the liquid-liquid interface have long been used and investigated in a number of different applications. The interfacial adsorption of particles can be induced by adjusting the particle wetting behavior in the liquid media. Here, we report a new approach to prepare stable oil-in-water emulsions by tailoring the wetting behavior of colloidal particles in water using short amphiphilic molecules. We illustrate the method using hydrophilic metal oxide particles initially dispersed in the aqueous phase. The wettability of such particles in water is reduced by an in situ surface hydrophobization that induces particle adsorption at oil-water interfaces. We evaluate the conditions required for particle adsorption at the liquid-liquid interface and discuss the effect of the emulsion initial composition on the final microstructure of oil-water mixtures containing high concentrations of alumina particles modified with short carboxylic acids. This new approach for emulsion preparation can be easily applied to a variety of other metal oxide particles.

Multimaterial magnetically assisted 3D printing of composite materials

3D printing has become commonplace for the manufacturing of objects with unusual geometries. Recent developments that enabled printing of multiple materials indicate that the technology can potentially offer a much wider design space beyond unusual shaping. Here we show that a new dimension in this design space can be exploited through the control of the orientation of anisotropic particles used as building blocks during a direct ink-writing process. Particle orientation control is demonstrated by applying low magnetic fields on deposited inks pre-loaded with magnetized stiff platelets. Multimaterial dispensers and a two-component mixing unit provide additional control over the local composition of the printed material. The five-dimensional design space covered by the proposed multimaterial magnetically assisted 3D printing platform (MM-3D printing) opens the way towards the manufacturing of functional heterogeneous materials with exquisite microstructural features thus far only accessible by biological materials grown in nature.

Magnetically assisted slip casting of bioinspired heterogeneous composites

Natural composites are often heterogeneous to fulfil functional demands. Manufacturing analogous materials remains difficult, however, owing to the lack of adequate and easily accessible processing tools. Here, we report an additive manufacturing platform able to fabricate complex-shaped parts exhibiting bioinspired heterogeneous microstructures with locally tunable texture, composition and properties, as well as unprecedentedly high volume fractions of inorganic phase (up to 100%). The technology combines an aqueous-based slip-casting process with magnetically directed particle assembly to create programmed microstructural designs using anisotropic stiff platelets in a ceramic, metal or polymer functional matrix. Using quantitative tools to control the casting kinetics and the temporal pattern of the applied magnetic fields, we demonstrate that this approach is robust and can be exploited to design and fabricate heterogeneous composites with thus far inaccessible microstructures. Proof-of-concept examples include bulk composites with periodic patterns of microreinforcement orientation, and tooth-like bilayer parts with intricate shapes exhibiting site-specific composition and texture.

Materials from foams and emulsions stabilized by colloidal particles

Foams and emulsions stabilized by colloidal particles can lead to new materials with unique structures and properties. In this Highlight article, we describe the underlying mechanisms of this new enabling technology, highlighting some of the processing routes to obtain capsules and porous structures for a variety of applications.

Stretchable heterogeneous composites with extreme mechanical gradients

Heterogeneous composite materials with variable local stiffness are widespread in nature, but are far less explored in engineering structural applications. The development of heterogeneous synthetic composites with locally tuned elastic properties would allow us to extend the lifetime of functional devices with mechanically incompatible interfaces, and to create new enabling materials for applications ranging from flexible electronics to regenerative medicine. Here we show that heterogeneous composites with local elastic moduli tunable over five orders of magnitude can be prepared through the site-specific reinforcement of an entangled elastomeric matrix at progressively larger length scales. Using such a hierarchical reinforcement approach, we designed and produced composites exhibiting regions with extreme soft-to-hard transitions, while still being reversibly stretchable up to 350%. The implementation of the proposed methodology in a mechanically challenging application is illustrated here with the development of locally stiff and globally stretchable substrates for flexible electronics.