The ability to pattern materials in three dimensions is critical for several technological applications, including composites, microfluidics, photonics, and tissue engineering. Direct-write assembly allows one to design and rapidly fabricate materials in complex 3D shapes without the need for expensive tooling, dies, or lithographic masks. Here, recent advances in direct ink writing are reviewed with an emphasis on the push towards finer feature sizes. Opportunities and challenges associated with direct ink writing are also highlighted.

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Direct ink writing of 3D functional materials

Slip occurs in the flow of two-phase systems because of the displacement of the disperse phase away from solid boundaries. This arises from steric, hydrodynamic, viscoelastic and chemical forces and constraints acting on the disperse phase immediately adjacent to the walls. The enrichment of the boundary near the wall with the continuous (and usually low-viscosity) phase means that any flow of the fluid over the boundary is easier because of the lubrication effect. Because this effect is usually confined to a very narrow layer — with typical thickness of 0.1–10 μm—it so resembles the slip of solids over surfaces that it has historically been given the same terminology. The restoring force for all the forces that cause an increase in concentration is usually osmotic, and this will always limit the effective slip. In dilute systems, concentration gradients can be present over relatively large distances out from walls, giving what might be interpreted on an overall basis as a thick solvent-only layer. However, as the concentration of the system increases, the layer gets thinner and thinner because it is more difficult to create with the large reverse osmotic force present. However, the enormous increase in the bulk viscosity with increase in concentration means that although thinner, the layer becomes, paradoxically, even more important. Slip manifests itself in such a way that viscosity measured in different size geometries gives different answers if calculated the normal way — in particular the apparent viscosity decreases with decrease in geometry size (e.g. tube radius). Also, in single flow curves unexpected lower Newtonian plateaus are sometimes seen, with an apparent yield stress at even lower stresses. Sudden breaks in the flow curve can also be seen. Large particles as the disperse phase (remember flocs are large particles), with a large dependence of viscosity on the concentration of the dispersed phase are the circumstances which can give slip, especially if coupled with smooth walls and small flow dimensions. The effect is usually greatest at low speeds/flow rates. When the viscometer walls and particles carry like electrostatic charges and the continuous phase is electrically conducted, slip can be assumed. In many cases we need to characterise the slip effects seen in viscometers because they will also be seen in flow in smooth pipes and condults in manufacturing plants. This is usually done by relating the wall shear stress to a slip velocity using a power-law relationship. When the bulk flow has also been characterized, the flow in real situations can be calculated. To characterise slip, it is necessary to change the size of the geometry, and the results extrapolated to very large size to extract unambigouos bulk-flow and slip data respectively. A number of mathematical manipulations are necessary to retrieve these data. We can make attempts to eliminate slip by altering the physical or chemical character of the walls. This is usually done physically by roughening or profiling, but in the extreme, a vane can be used. This latter geometry has the advantage of being easy to make and clean. In either case—by extrapolation or elimination—we end up with the bulk flow properties. This is important in situations where we are trying to understand the microstructure/flow interactions.

A review of the slip (wall depletion) of polymer solutions, emulsions and particle suspensions in viscometers: its cause, character, and cure

1. Introduction to colloid science and rheology 2. Hydrodynamic effects 3. Brownian hard spheres 4. Stable colloidal suspensions 5. Non-spherical particles 6. Weakly flocculated suspensions 7. Thixotropy 8. Shear thickening 9. Rheometry of suspensions 10. Suspensions in viscoelastic media 11. Advanced topics.

Colloidal Suspension Rheology

The ability to pattern ceramic materials in three dimensions (3D) is critical for structural, functional, and biomedical applications. One facile approach is direct ink writing (DIW), in which 3D structures are built layer-by-layer through the deposition of colloidal- or polymer-based inks. This approach allows one to design and rapidly fabricate ceramic materials in complex 3D shapes without the need for expensive tooling, dies, or lithographic masks. In this feature article, we present both droplet- and filament-based DIW techniques. We focus on the various ink designs and their corresponding rheological behavior, ink deposition mechanics, potential shapes and the toolpaths required, and representative examples of 3D ceramic structures assembled by each technique. The opportunities and challenges associated with DIW are also highlighted.

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Direct Ink Writing of Three‐Dimensional Ceramic Structures

Mesoscale periodic structures have been fabricated via directed assembly of colloidal inks. Concentrated colloidal gels with tailored viscoelastic properties were designed to form self-supporting f...

Colloidal inks for directed assembly of 3-D periodic structures

It is demonstrated that weakly flocculated, concentrated colloidal dispersions show slip flow when sheared between smooth concentric cylinders. The precise pattern of behavior seen depends upon the stress and upon how long the flow is left to establish prior to measurement. With delay times of order hours, slip is not seen until a critical stress is exceeded (typically about 1 Pa) and, thus, the true low‐shear viscosity can be determined provided care is taken to ensure the stress does not exceed the critical level. With short delay times of order minutes, slip is seen irrespective of how small the stress is and the low‐shear viscosity can be underestimated by several orders of magnitude. Comparisons of flow curves obtained using smooth and roughened cylinders show that slip only occurs at the inner cylinder, and also that bulk flow is re‐established at higher stresses where the dispersions start to shear thin. The apparent low‐shear, relative viscosity measured in the presence of slip appears, to a first...

Anthony J. Morton‐Jones

Papers

The rheology of concentrated dispersions of weakly attracting colloidal particles with and without wall slip