<p>  </p> <p>High-resolution enclosed channels/fibers are highly demanded by different disciplines such as microfluidic channels for chemical synthesis, bioreactors for drug metabolism, magnetic locomotor for drug delivery, and wearable devices for motion detection. However, the current fabrication techniques for enclosed channels/fibers are restricted to a few millimeters in size. Their manufacturing often involves time and energy-consuming multi-step processes with insufficient resolution. In this work, we demonstrate a novel co-flow-enabled fabrication method to resolve the technological restrictions in the fabrication of high-resolution enclosed channels/fibers with efficient production time, controllable morphologies, and high throughput manner.</p> <p>An epoxy-based enclosed microfluidic channel was first built. A non-reactive paraffin oil and a liquid resin were pumped into a 3D-printed co-flow generator and worked as core and shell fluids, respectively. The epoxy resin was cured by external heat stimulus. As a result, the reaction region was limited between the generator wall surface and the boundary of core flow, eliminating the need for precise control over the curing system. The experiment was successfully conducted to cure build resin channel inside copper and resin tubes with good shell thickness.</p> <p>Conductive hollow hydrogel microfibers were also fabricated by this method. Sodium Alginate and Calcium Chloride were chosen as the shell and core flows, respectively. The ionic crosslinking happens at the boundary of two flows and expands outwards across the radial direction. Thus, the diameter of the hollow channel can be easily adjusted by tuning the flow rate and the size of the core flow injection needle. PEDOT: PSS, a conductive polymer, was mixed with Sodium Alginate to impart fibers with excellent electrical conductivity. The synthesized hollow microfibers have shown their functionality in stretching movement detection by serving as a fundamental building element of motion sensors. </p>

<p>Textiles have gained popularity in wearable products due to their potential for wearability, comfort, flexibility, breathability, and seamless fit to the human body. The growing demand for remote telehealth monitoring has led to advancements in the field of e-textiles. Various approaches, such as dip coating, screen printing, inkjet printing, and vapor deposition, are utilized to overcoat fabrics with active nanomaterials. However, practical deployment still faces challenges due to a lack of rapid prototyping for scalable and customizable e-textiles. To meet the requirements of large-scale batch production, high-resolution electrode line width, and long-term durability, new platform technologies have been established to convert existing textiles into multifunctional e-textiles. These studies have also revealed the process-structure-property relationships of various e-textiles.</p> <p>Chapter I overviews the recent results and current limitations of e-textiles in wearable sensing and display. Since people stay and work in various circumstances, continuous monitoring of physical, electrophysiological signals on skin in ambulatory manners is necessary to evaluate hazardous situation or chronicle symptoms. For these reasons, fabrication of smart e-textiles is crucial. In this chapter, various conductive materials, overcoating methods, and sensor structures for physical and electrophysiological sensors are reviewed. In addition, as a useful user communication tool with different sensor system, e-textile formats of displays are developed. The comprehensive e-textile displays from DC-driven to AC-driven are presented.</p> <p>Chapter II introduces a dual-regime spray technique that enables the direct writing of functional nanoparticles onto commercial 4-way stretchable textiles up to a meter scale with high-resolution mask-free patterning. The resulting e-textiles maintain the intrinsic properties of the fabric and can conform to various body shapes, enabling high-fidelity recording of physiological and electrophysiological signals under ambulatory conditions. Field tests have shown the potential of these e-textiles for minimally obtrusive remote telehealth monitoring of large animals.</p> <p>Chapter III presents an in-situ polymerization and patterning technique that utilizes the dual-regime spray method to synthesize conductive polymers directly onto commercial stretch textiles. The resulting e-textiles are utilized for strain sensors that conform closely to the human body, providing exceptional measurement accuracy and fidelity in capturing physical signals and motion detections.</p> <p>Conclusion section summarizes this dissertation with pointing out important results and discussions of each study. As an innovative additive manufacturing technology, dual-regime spray system, was established and developed to open new field in manufacture of e-textile. At last of this section, the potential research opportunities and perspectives are addressed. </p>

<p>  </p> <p>Printed electronics (PE) is one of the fastest growing technologies in the 21^st century. Recent reports have shown that PE market will reach 4.9 billion by 2032. PE refers to additive deposition of materials to fabricate electrical circuits, interconnects, and devices. </p> <p>The quest for developing nondestructive processes that enables additive manufacturing of low-cost PEs on heat-sensitive substrates with novel functionalities has resulted in several recent developments in the field which includes investigation of selective and optical sintering processes such as photonic sintering and laser sintering, to name a few. Broadly, this dissertation is an effort to study these sintering technologies for additive manufacturing of bimodal (metal/metal, metal/inorganic, and metal/organic) printed material compositions.  </p> <p>In the first section, nondestructive sintering technologies is combined with chemical sintering to develop bimodal metallic conductive pastes for the fabrication of biodegradable and non-biodegradable printed devices for applications in food packaging and wireless smart drug delivery.</p> <p>Next, a process is developed via near-infrared (NIR) technology to enable soldering and mounting electrical components onto printed materials using low-temperature bimodal metal/organic solder pastes. The developed optimized process is used to fabricate a flexible printed hybrid device for remote assessment of the wound exudate absorption in dressings.</p> <p>Lastly, laser processing is used to fabricate an antibacterial bimodal silver containing glass ceramics coating directly on temperature-sensitive polymeric surgical meshes. The integrated bioceramic coating on the mesh exhibits long-lasting antibacterial properties against Gram-positive and Gram-negative strains of bacteria. </p> <p>The results of this dissertation will open a new route of research to fabricate low-cost devices with bimodal materials with applications in medical device, healthcare, and packaging industries. </p> <p><br></p>