Yajiang Ding

Versatile, kinetically controlled, high precision electrohydrodynamic writing of micro/nanofibers

Direct writing of hierarchical micro/nanofibers have recently gained popularity in flexible/stretchable electronics due to its low cost, simple process and high throughput. A kinetically controlled mechanoelectrospinning (MES) is developed to directly write diversified hierarchical micro/nanofibers in a continuous and programmable manner. Unlike conventional near-field electrospinning, our MES method introduces a mechanical drawing force, to simultaneously enhance the positioning accuracy and morphology controllability. The MES is predominantly controlled by the substrate speed, the nozzle-to-substrate distance, and the applied voltage. As a demonstration, smooth straight, serpentine, self-similar, and bead-on-string structures are direct-written on silicon/elastomer substrates with a resolution of 200 nm. It is believed that MES can promote the low-cost, high precision fabrication of flexible/stretchable electronics or enable the direct writing of the sacrificial structures for nanoscale lithography.

Near-field behavior of electrified jet under moving substrate constrains

We investigate the dynamics and shapes of electrified jet deposited onto a moving substrate in near-field electrospinning. At low speed, drag effect imposes on the jet and makes it buckling to a ‘heel’. As the ‘heel’ continues to move far away, a restoring force is accumulated until it is large enough to make an ‘out of the plane deformation’, which will also introduce torsion for the jet and turns it into a rotation state. When the speed increases, stretching effect makes jet drawing to a stable catenary shape. The ‘heel’ is a transition stage between catenary and rotation state due to the buckling of the jet. Moreover, the transformation from the ‘heel’ to ‘catenary’ is validated by modeling the jet as electrified filament. The simulation results show that the speed brings the pulling force exerted on the jet tail and it only depends on the substrate speed. The works provide a better understanding the effect mechanism of the substrate speed on the fiber morphology.

Addressable multi-nozzle electrohydrodynamic jet printing with high consistency by multi-level voltage method

It is critical and challenging to achieve the individual jetting ability and high consistency in multi-nozzle electrohydrodynamic jet printing (E-jet printing). We proposed multi-level voltage method (MVM) to implement the addressable E-jet printing using multiple parallel nozzles with high consistency. The fabricated multi-nozzle printhead for MVM consists of three parts: PMMA holder, stainless steel capillaries (27G, outer diameter 400 μm) and FR-4 extractor layer. The key of MVM is to control the maximum meniscus electric field on each nozzle. The individual jetting control can be implemented when the rings under the jetting nozzles are 0 kV and the other rings are 0.5 kV. The onset electric field for each nozzle is ∼3.4 kV/mm by numerical simulation. Furthermore, a series of printing experiments are performed to show the advantage of MVM in printing consistency than the “one-voltage method” and “improved E-jet method”, by combination with finite element analyses. The good dimension consistency (274μm, 276μm, 280μm) and position consistency of the droplet array on the hydrophobic Si substrate verified the enhancements. It shows that MVM is an effective technique to implement the addressable E-jet printing with multiple parallel nozzles in high consistency.

Large-Scale Direct-Writing of Aligned Nanofibers for Flexible Electronics

Nanofibers/nanowires usually exhibit exceptionally low flexural rigidities and remarkable tolerance against mechanical bending, showing superior advantages in flexible electronics applications. Electrospinning is regarded as a powerful process for this 1D nanostructure; however, it can only be able to produce chaotic fibers that are incompatible with the well-patterned microstructures in flexible electronics. Electro-hydrodynamic (EHD) direct-writing technology enables large-scale deposition of highly aligned nanofibers in an additive, noncontact, real-time adjustment, and individual control manner on rigid or flexible, planar or curved substrates, making it rather attractive in the fabrication of flexible electronics. In this Review, the ground-breaking research progress in the field of EHD direct-writing technology is summarized, including a brief chronology of EHD direct-writing techniques, basic principles and alignment strategies, and applications in flexible electronics. Finally, future prospects are suggested to advance flexible electronics based on orderly arranged EHD direct-written fibers. This technology overcomes the limitations of the resolution of fabrication and viscosity of ink of conventional inkjet printing, and represents major advances in manufacturing of flexible electronics.

Helix Electrohydrodynamic Printing of Highly Aligned Serpentine Micro/Nanofibers

Micro/nano serpentine structures have widespread applications in flexible/stretchable electronics; however, challenges still exist for low-cost, high-efficiency and controllable manufacturing. Helix electrohydrodynamic printing (HE-printing) has been proposed here to realize controllable direct-writing of large area, highly aligned serpentine micro/nanofibers by introducing the rope coiling effect into printing process. By manipulating the flying trajectory and solidification degree of the micro/nano jet, the solidified micro/nanofiber flying in a stabilized helical manner and versatile serpentine structures deposited on a moving collector have been achieved. Systematic experiments and theoretical analysis were conducted to study the transformation behavior and the size changing rules for various deposited microstructures, and highly aligned serpentine microfibers were directly written by controlling the applied voltage, nozzle-to-collector distance and collector velocity. Furthermore, a hyper-stretchable piezoelectric device that can detect stretching, bending and pressure has been successfully fabricated using the printed serpentine micro/nanofibers, demonstrating the potential of HE-printing in stretchable electronics manufacturing.

Ultra-Stretchable Piezoelectric Nanogenerators via Large-Scale Aligned Fractal Inspired Micro/Nanofibers

Stretchable nanogenerators that directly generate electricity are promising for a wide range of applications in wearable electronics. However, the stretchability of the devices has been a long-standing challenge. Here we present a newly-designed ultra-stretchable nanogenerator based on fractal-inspired piezoelectric nanofibers and liquid metal electrodes that can withstand strain as large as 200%. The large-scale fractal poly(vinylidene fluoride) (PVDF) micro/nanofibers are fabricated by combination of helix electrohydrodynamic printing (HE-Printing) and buckling-driven self-assembly. HE-Printing exploits “whipping/buckling” instability of electrospinning to deposit serpentine fibers with diverse geometries in a programmable, accurately positioned, and individually-controlled manner. Self-organized buckling utilizes the driven force from the prestrained elastomer to assemble serpentine fibers into ultra-stretchable fractal inspired architecture. The nanogenerator with embedded fractal PVDF fibers and liquid-metal microelectrodes demonstrates high stretchability (>200%) and electricity (currents >200 nA), it can harvest energy from all directions by arbitrary mechanical motion, and the rectified output has been applied to charge the commercial capacitor and drive LEDs, which enables wearable electronics applications in sensing and energy harvesting.