Materials and Strategies to Enhance Melt Electrowriting Potential

Materials and Strategies to Enhance Melt Electrowriting Potential

2024 | Paula G. Saiz, Ander Reizabal, Jose Luis Vilas-Vilela, Paul D. Dalton, and Senentxu Lanceros-Mendez
Melt electrowriting (MEW) is an emerging additive manufacturing technology that enables the precise deposition of continuous polymeric microfibers, allowing for the creation of high-resolution constructs. This review explores MEW's characteristics from a materials science perspective, emphasizing the diverse range of materials and composites processed by this technique and their current and potential applications. It also explores the prospects offered by postprinting processing techniques and the synergy achieved by combining MEW with other manufacturing methods. MEW has been revolutionized by the introduction of active properties or additional functionalities through novel polymer processing strategies, the incorporation of functional fillers, postprocessing, or the combination with other techniques. While extensively explored in biomedical applications, MEW's potential in other fields remains untapped. The review highlights the untapped potentials of MEW, aiming to inspire research groups across various fields to leverage this technology for innovative endeavors. MEW is an electrohydrodynamic (EHD) technology that enables the fabrication of high-resolution 3D porous macrostructures in a solvent-free mode. It combines thermal energy and electrical forces, allowing for the controlled extrusion of molten polymers through a nozzle that subsequently forms well-ordered continuous micrometric fibers upon material solidification. The basic configuration of MEW devices comprises a heated polymer feeding system, a three-axis positioning configuration, and a high-voltage source. Collectors exhibit variability and have been tested in various forms, including flat and static designs, cylindrical and dynamic configurations, spherical collectors, and other custom features. The electric field generated between the printhead and the collector induces charges on a molten drop, giving rise to the Taylor Cone as these charges overcome the surface tension of the molten material and the melt is jetted toward the collector. The applied charges sufficiently minimize EHD instabilities so that the jet travels vertically toward the collector, allowing for precise control of its deposition by adjusting the relative positioning of the printhead. MEW's remarkable capability to suppress Plateau–Rayleigh instabilities, coupled with the high viscosity and low conductivity of melt fluids, empowers precise control over very fine jets. By defining printhead relative movement, usually by computer numerical control languages (G-code), fiber placement can be readily controlled. This, combined with adjustments in other printing parameters, enables the fabrication of high-resolution 3D porous structures in a layer-by-layer mode. However, due to charge accumulation in fibers, challenges remain regarding the maximum number of layers that can be stacked. Recent research has successfully achieved a 7.1 mm thick MEW structure through meticulous adjustments of voltage and working distance during the printing process to maintain a constant electrostatic force. The review discusses the variety of polymers suitable for MEW, surpassing the landscape described in previous reviews. The proliferation of processable polymers now exceeds three times the number previously reported, with a fourfold increase in the use of composite materials. This surge is expected to continue, driven by enhanced accessibility to the techniqueMelt electrowriting (MEW) is an emerging additive manufacturing technology that enables the precise deposition of continuous polymeric microfibers, allowing for the creation of high-resolution constructs. This review explores MEW's characteristics from a materials science perspective, emphasizing the diverse range of materials and composites processed by this technique and their current and potential applications. It also explores the prospects offered by postprinting processing techniques and the synergy achieved by combining MEW with other manufacturing methods. MEW has been revolutionized by the introduction of active properties or additional functionalities through novel polymer processing strategies, the incorporation of functional fillers, postprocessing, or the combination with other techniques. While extensively explored in biomedical applications, MEW's potential in other fields remains untapped. The review highlights the untapped potentials of MEW, aiming to inspire research groups across various fields to leverage this technology for innovative endeavors. MEW is an electrohydrodynamic (EHD) technology that enables the fabrication of high-resolution 3D porous macrostructures in a solvent-free mode. It combines thermal energy and electrical forces, allowing for the controlled extrusion of molten polymers through a nozzle that subsequently forms well-ordered continuous micrometric fibers upon material solidification. The basic configuration of MEW devices comprises a heated polymer feeding system, a three-axis positioning configuration, and a high-voltage source. Collectors exhibit variability and have been tested in various forms, including flat and static designs, cylindrical and dynamic configurations, spherical collectors, and other custom features. The electric field generated between the printhead and the collector induces charges on a molten drop, giving rise to the Taylor Cone as these charges overcome the surface tension of the molten material and the melt is jetted toward the collector. The applied charges sufficiently minimize EHD instabilities so that the jet travels vertically toward the collector, allowing for precise control of its deposition by adjusting the relative positioning of the printhead. MEW's remarkable capability to suppress Plateau–Rayleigh instabilities, coupled with the high viscosity and low conductivity of melt fluids, empowers precise control over very fine jets. By defining printhead relative movement, usually by computer numerical control languages (G-code), fiber placement can be readily controlled. This, combined with adjustments in other printing parameters, enables the fabrication of high-resolution 3D porous structures in a layer-by-layer mode. However, due to charge accumulation in fibers, challenges remain regarding the maximum number of layers that can be stacked. Recent research has successfully achieved a 7.1 mm thick MEW structure through meticulous adjustments of voltage and working distance during the printing process to maintain a constant electrostatic force. The review discusses the variety of polymers suitable for MEW, surpassing the landscape described in previous reviews. The proliferation of processable polymers now exceeds three times the number previously reported, with a fourfold increase in the use of composite materials. This surge is expected to continue, driven by enhanced accessibility to the technique
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[slides and audio] Materials and Strategies to Enhance Melt Electrowriting Potential