Highly structured 3D pyrolytic carbon electrodes derived from additive manufacturing technology

Rezaei, Babak; Pan, Jesper Yue; Gundlach, Carsten; Keller, Stephan Sylvest

doi:10.1016/j.matdes.2020.108834

Cited by 43 publications

(56 citation statements)

References 51 publications

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“…As schematically illustrated in Figure 1 , first, free-standing 3D polymer precursor structures in a 3D reticular configuration were produced with SLA printing of a pyrolyzable resin ( Figure 1 a). 30 Figure 1 b schematically shows the subsequent in situ synthesis of MnO x nanostructures directly on the surface of the 3D-printed resin. Under very mild acidic conditions, a slow acidic reduction of potassium permanganate leads to the nucleation and self-assembly of nanostructures on the surface of the 3D-printed structure.…”

Section: Resultsmentioning

confidence: 99%

“…In previous work, a commercial photopolymer (Formlabs high-temperature resin, HTR), composed of acrylated monomers and methacrylated oligomers, 29 was employed to print complex 3D structures and identified as pyrolyzable material. 30 More details about the physicochemical properties of the commercial photopolymer resin utilized in this research are summarized in Table S1 . For fabrication of the complex 3D polymer precursor structures, 3D models were designed using Fusion360 software and directly SLA-printed (support-free printing) on the surface of a 6-in.…”

Section: Experimental Approachmentioning

confidence: 99%

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Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Rezaei

Hansen

Keller

2021

ACS Appl. Nano Mater.

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The development of permeable three-dimensional (3D) macroporous carbon architectures loaded with active pseudocapacitive nanomaterials offers hybrid supercapacitor (SC) materials with higher energy density, shortened diffusion length for ions, and higher charge–discharge rate capability and thereby is highly relevant for electrical energy storage (EES). Herein, structurally complex and tailorable 3D pyrolytic carbon/Mn 3 O 4 hybrid SC electrode materials are synthesized through the self-assembly of MnO 2 nanoflakes and nanoflowers onto the surface of stereolithography 3D-printed architectures via a facile wet chemical deposition route, followed by a single thermal treatment. Thermal annealing of the MnO 2 nanostructures concurrent with carbonization of the polymer precursor leads to the formation of a 3D hybrid SC electrode material with unique structural integrity and uniformity. The microstructural and chemical characterization of the hybrid electrode reveals the predominant formation of crystalline hausmannite-Mn 3 O 4 after the pyrolysis/annealing process, which is a favorable pseudocapacitive material for EES. With the combination of the 3D free-standing carbon architecture and self-assembled binder-free Mn 3 O 4 nanostructures, electrochemical capacitive charge storage with very good rate capability, gravimetric and areal capacitances (186 F g –1 and 968 mF cm –2 , respectively), and a long lifespan (>92% after 5000 cycles) is demonstrated. It is worth noting that the gravimetric capacitance value is obtained by considering the full mass of the electrode including the carbon current collector. When only the mass of the pseudocapacitive nanomaterial is considered, a capacitance value of 457 F g –1 is achieved, which is comparable to state-of-the-art Mn 3 O 4 -based SC electrode materials.

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Section: Resultsmentioning

confidence: 99%

Section: Experimental Approachmentioning

confidence: 99%

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Rezaei

Hansen

Keller

2021

ACS Appl. Nano Mater.

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“…Furthermore, the high temperature is typically kept stable for several hours to allow the carbon to reorganize, resulting in carbon surfaces with very low roughness and porosity [ 24 ]. However, several studies have reported increased porosity of pyrolytic carbon for faster ramping rates due to more intense degassing [ 43 , 44 ]. In LLP, the temperature ramping is extremely fast in comparison, regardless of scan speed, and the time that the exposed volume remains at this high temperature is extremely short.…”

Section: Resultsmentioning

confidence: 99%

Selective Direct Laser Writing of Pyrolytic Carbon Microelectrodes in Absorber-Modified SU-8

et al. 2021

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Pyrolytic carbon microelectrodes (PCMEs) are a promising alternative to their conventional metallic counterparts for various applications. Thus, methods for the simple and inexpensive patterning of PCMEs are highly sought after. Here, we demonstrate the fabrication of PCMEs through the selective pyrolysis of SU-8 photoresist by irradiation with a low-power, 806 nm, continuous wave, semiconductor-diode laser. The SU-8 was modified by adding Pro-Jet 800NP (FujiFilm) in order to ensure absorbance in the 800 nm range. The SU-8 precursor with absorber was successfully converted into pyrolytic carbon upon laser irradiation, which was not possible without an absorber. We demonstrated that the local laser pyrolysis (LLP) process in an inert nitrogen atmosphere with higher laser power and lower scan speed resulted in higher electrical conductance. The maximum conductivity achieved for a laser-pyrolyzed line was 14.2 ± 3.3 S/cm, with a line width and thickness of 28.3 ± 2.9 µm and 6.0 ± 1.0 µm, respectively, while the narrowest conductive line was just 13.5 ± 0.4 µm wide and 4.9 ± 0.5 µm thick. The LLP process seemed to be self-limiting, as multiple repetitive laser scans did not alter the properties of the carbonized lines. The direct laser writing of adjacent lines with an insulating gap down to ≤5 µm was achieved. Finally, multiple lines were seamlessly joined and intersected, enabling the writing of more complex designs with branching electrodes and the porosity of the carbon lines could be controlled by the scan speed.

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“…However, this strategy does not appear to work for all commercial resins, with some printed parts collapsing following pyrolysis. [ 290 ] Fundamentally, it depends on the chemical composition of the starting resin. As expected, pyrolysis will induce both mass loss and linear shrinkage, which can be as high as 95% and 60%, respectively, and will depend on both the pyrolysis temperature and heating rate.…”

Section: Additive Manufacturing Of Ec Biosensorsmentioning

confidence: 99%

Section: Additive Manufacturing Of Ec Biosensorsmentioning

confidence: 99%

Additive Manufacturable Materials for Electrochemical Biosensor Electrodes

Elbadawi

Ong

Pollard

et al. 2020

Adv Funct Materials

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With the impending Industrial Revolution 4.0, the information produced by sensors will be central in many applications. This includes the healthcare sector, where affordable healthcare and precision medicine are highly sought after. Electrochemical sensors have the potential to produce affordable, high sensitivity and specificity, intuitive, and rapid point‐of‐care diagnostics. Underpinning these achievements is the choice of material and the fabrication thereof. In this review, the different types of materials used in electrochemical biosensors are reported, with a focus on synthetic conductive materials. The review demonstrates that there is an abundance of materials to select from, and compositing different types of materials further widens their applicability in biosensors. In addition, the fabrication of such materials using the state‐of‐the‐art of fabrication technology, additive manufacturing (AM), is also detailed. The need for compositing is evident in AM, as the feedstock for certain AM technologies is inherently nonconductive. Both material choice and fabrication technologies limitations are also discussed to highlight opportunities for growth. The review highlights how recent technological advancements have the potential to drive the healthcare industry toward achieving its primary goals.

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Highly structured 3D pyrolytic carbon electrodes derived from additive manufacturing technology

Cited by 43 publications

References 51 publications

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Selective Direct Laser Writing of Pyrolytic Carbon Microelectrodes in Absorber-Modified SU-8

Additive Manufacturable Materials for Electrochemical Biosensor Electrodes

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Highly structured 3D pyrolytic carbon electrodes derived from additive manufacturing technology

Cited by 43 publications

References 51 publications

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn3O4 Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn3O4 Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Selective Direct Laser Writing of Pyrolytic Carbon Microelectrodes in Absorber-Modified SU-8

Additive Manufacturable Materials for Electrochemical Biosensor Electrodes

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Product

Resources

About

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes

Stereolithography-Derived Three-Dimensional Pyrolytic Carbon/Mn₃O₄ Nanostructures for Free-Standing Hybrid Supercapacitor Electrodes