The advent of additive manufacturing has opened up new frontiers in developing metal structures that can have complex geometries, composite structures made of dissimilar metals, and metal structures with embedded sensing and actuation capabilities. These types of structures are possible with ultrasonic additive manufacturing (UAM); a novel manufacturing technology that combines additive manufacturing through the ultrasonic welding of thin metal foils with computer numerical control (CNC) milling. However, the process suffers from a critical limitation, i.e., a range of build heights within which bonding between a foil and the substrate cannot be originated. <br>This work has two research objectives, the first is a fundamental understanding of the complex dynamic interaction between the substrate and ultrasonic horn, or sonotrode. Specifically, it focuses on the effects that specific modes of vibration have on the dynamic response of the substrate. The second objective is to utilize the UAM process to create metal structures with an embedded sensor that can detect contact or impact. In addressing the first objective, a semi-analytical model was developed to determine the response to three forcing descriptions that approximate the interfacial friction between the foil and substrate induced by sonotrode compression and excitation. Several observations can be seen in the results: as the height increases the dominant modes of vibration change, the modes of vibration excited also change during a single weld cycle as the sonotrode travels across the length of the substrate, and finally the three forcing models do not have a significant impact on the substrate response trends with height and during the weld cycle. <br>In addressing the second objective, three prototypes were created by embedding a triboelectric nanogenerator (TENG) sensor within an AL3003 metal-matrix. TENGs utilize contact electrification between surfaces of dissimilar materials, typically polymers, combined with electrostatic induction to generate electrical energy from a mechanical excitation. The sensors demonstrate a discernible response over a 1-5 Hz frequency range. In addition, the sensors have a linear relationship between output voltage and a mechanically applied load, and have the ability to sense contact through both touch and due to an impacting object.

Traditional fabrication methods used to manufacture biosensors for physiological, therapeutics, or health monitoring purposes are complex and rely on costly materials, which has hindered their adoption as single-use medical devices. The development of a new kind of wearable and implantable electronics relying on inexpensive materials for their manufacturing will pave the way towards the ubiquitous adoption of sticker-like health tracking devices.<div>One of growing and most promising applications for biosensors is the continuous health monitoring using mechanically soft, stretchable sensors. While these healthcare devices showed an excellent compatibility with human tissues, they still need highly trained personnel to perform multi-step, prolonged fabrication for several functioning layers of the device. In this dissertation, I propose low-cost, scalable, simple, and rapid manufacturing techniques to fabricate multifunctional epidermal and implantable sensors to monitor a range of biosignals including heart, muscle, or eye activity to characterizing of biofuids such as sweat. I have also used these devices as an implant to provide heat therapy for muscle regeneration and optical stimulation of neurons using optogenetics. These devices have also combined with those of triboelectric<br>nanogenerators to realize self-powered sensors for monitoring imperceptible mechanical biosignals such as respiratory and pulse rate.</div><div>Food health and safety has also emerged as another important frontier to develop biosensors and improve the human health and quality of life. The recent progresses on detecting microbial activity inside foods or their packages rely on development of highly functional materials. The existing materials for fabrication of food sensors, however,<br>are often costly and toxic for human health or the environment. In this dissertation, I proposed biocompatible food sensors using protein/PCL microfibers to reinforce the protein microfibrous structure in humid conditions and exploit their excellent hygroscopic properties to sense biogenic gas, as an indicator for early detection of food spoilage. Finally, my battery-free food sensors are capable of monitoring food safety with no need of extra measurement devices. Collectively, this dissertation proposes cost-effective solutions to solve human health issues, enabled by developing low-cost, functional materials and exploiting simple fabrication techniques.<br></div>