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Electrohydrodynamic Film Patterning (EHD-FP) for Rapid Fabrication of Kagome Lattices
Conferences & Talks

2015 MRS Fall Meeting & Exhibit

1 December 2015



We have developed a novel approach for rapidly fabricating large-area hierarchical material lattices based on electrohydrodynamic film patterning (EHD-FP). Using a controlled electric field and patterned electrodes, EHD-FP enables the rapid fabrication of hierarchical material films 20-40 µm in thickness with features at multiple length scales, including micron to sub-micron features. EHD-FP can be readily adapted to high speed, continuous roll-to-roll processing to create large area patterns and materials. Hierarchical materials are materials which concurrently realize functional features on multiple length scales (sub-micron up to a millimeter level). This allows large void space in a material structure to be filled with load bearing members, adding compliance to the material without significantly increasing the density. Hierarchical materials have the potential to be transformational for a variety of applications, enabling components which simultaneously offer the best performance attributes of ceramics, metals, and plastics. Researchers have pursued hierarchical material structures for almost 20 years, leveraging inspiration from both nature and architecture, but few have shown success in synthetically re-creating these structures at multiple length scales with techniques that scale to high-volume, low-cost production. We present our EHD-FP fabrication and mechanical testing results for two-dimensional (2D) hierarchical Kagome lattices made with ultraviolet (UV) curable polymers. Using the EHD-FP process, hierarchical films are easily and rapidly created with low viscosity UV cross-linked polymers. Our mechanical test results provide confirmation of some of the underlying mechanics for hierarchical materials showing a ~2X improvement in strength and modulus over bulk constituents. This material is based upon work supported by the Defense Advanced Research Projects Agency under Contract No. HR0011-14-C-0036.